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Mazda CX-7 PDF
Mazda CX-7 PDF
fm 1 ページ 2006年3月15日 水曜日 午後1時17分
2007 CONTENTS
Mazda Title Section
Manual SUSPENSION 02
FOREWORD DRIVELINE/AXLE 03
This manual contains on-vehicle service
and/or diagnosis procedures for the Mazda BRAKES 04
CX-7.
TRANSMISSION/TRANSAXLE 05
For proper repair and maintenance,
a thorough familiarization with this manual is STEERING 06
important, and it should always be kept in a
handy place for quick and easy reference. HEATER, VENTILATION & 07
AIR CONDITIONING (HVAC)
All the contents of this manual, including
drawings and specifications, are the latest RESTRAINTS 08
available at the time of printing.
As modifications affecting repair or BODY & ACCESSORIES 09
maintenance occur, relevant information
supplementary to this volume will be made ALPHABETICAL INDEX AI
available at Mazda dealers. This manual
should be kept up-to-date. © 2006 Mazda Motor Corporation
PRINTED IN U.S.A., FEBRUARY 2006
Mazda Motor Corporation reserves the right Form No. 1871–1U–06B
to alter the specifications and contents of Part No. 9999–95–034B–07
this manual without obligation or advance
notice.
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN), and related materials
shown on the following page.
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RELATED MATERIALS
End of Toc
NG: GENERAL INFORMATION
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GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN) CODE
id000000100200
J M3ER 293 *7 # 12 3 4 5 6
Serial No.
0= Hiroshima
Plant 1= Hofu
Check digit *= 0 to 9, X
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End Of Sie
VEHICLE IDENTIFICATION NUMBER (VIN)
id000000100300
JM3 ER29L*7# 100001—
JM3 ER293*7# 100001—
End Of Sie
WM: GENERAL INFORMATION
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GENERAL INFORMATION
HOW TO USE THIS MANUAL
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Range of Topics
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
— Removal/Installation 00-00
— Disassembly/Assembly
— Replacement
— Inspection
— Adjustment
• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
• Inspection and adjustment procedures are
divided into steps. Important points regarding the SHOWS PROCEDURE ORDER
location and contents of the procedures are FOR SERVICE
explained in detail and shown in the illustrations.
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}
49 1232 670A
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GENERAL INFORMATION
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
SHOWS SERVICE
Procedure ITEM (S)
INDICATES RELEVANT
1
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION REFERENCES THAT NEED
1. Jack up the rear of the vehicle and support it with safety stands. TO BE FOLLOWED DURING
"Removal/Installation" 2. Remove the undercover. (See 01-10-4 Undercover Removal)
Portion 3. Remove in the order indicated in the table. INSTALLATION
4. Install in the reverse order of removal.
2 5. Inspect the rear wheel alignment and adjust it if necessary.
"Inspection After SHOWS SPECIAL
Installation" Portion 11 SERVICE TOOL (SST)
9 SST
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION
GREASE
FOR SERVICE 12 SST R
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS SHOWS EXPENDABLE PARTS
SST
3
5
6 SHOWS DETAILS
SST
GREASE
4 R
94—116 {9.5—11.9, 69—86}
2 118—156 {12.0—16.0, 87—115}
SHOWS TIGHTENING
1 R TORQUE UNITS
SHOWS REFERRAL
NOTES FOR SERVICE N·m {kgf·m, ft·lbf}
Lower Trailing Link Ball Joint, Upper Trailing Link 49 T028 304 UPPER TRAILING LINK
Ball Joint Removal Note 49 T028 305 LOWER TRAILING LINK
Remove the ball joint using the SSTs.
SHOWS SPECIAL
SERVICE TOOL (SST)
NO. KNUCKLE
49 T028 303
SHOWS REFERRAL
NOTES FOR
SERVICE
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GENERAL INFORMATION
Symbols
• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. use. These
symbols show application points or use of these materials during service.
Symbol Meaning Kind
00-00
New appropriate
OIL Apply oil engine oil or gear
oil
New appropriate
BRAKE Apply brake fluid
FLUID brake fluid
New appropriate
Apply automatic
automatic
transaxle/
ATF
transaxle/
transmission fluid
transmission fluid
Appropriate
Apply grease
GREASE
grease
Appropriate
SEALANT Apply sealant
sealant
O-ring, gasket,
R Replace part
etc.
Use SST or
SST equivalent
Appropriate tools
Advisory Messages
• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
• A Note provides added information that will help you to complete a particular procedure.
Specification
• The values indicate the allowable range when performing inspections or adjustments.
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GENERAL INFORMATION
Troubleshooting Procedure
Basic flow of troubleshooting
CUSTOMER ARRIVES
WITHOUT DTC
DIAGNOSE BY DTC
(ON-BOARD DIAGNOSTIC) DIAGNOSE BY SYMPTOM
DTC TABLE (SYMPTOM TROUBLESHOOTING)
DTC 1. DIAGNOSTIC INDEX
TROUBLESHOOTING 2. QUICK DIAGNOSIS CHART
FLOW (IF MENTIONED)
3. SYMPTOM
*: INDICATOR LIGHTS AND WARNING TROUBLESHOOTING
LIGHTS THAT INDICATE MALFUNCTIONS
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Diagnostic index
• The diagnostic index lists the symptoms of specific malfunctions. Select the symptoms related or most closely
relating to the malfunction.
Symptom troubleshooting
• Symptom troubleshooting quickly determines the location of the malfunction according to symptom type.
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GENERAL INFORMATION
Procedures for Use
Using the basic inspection (section 05)
• Perform the basic inspection procedure before symptom troubleshooting.
• Perform each step in the order shown.
• The reference column lists the location of the detailed procedure for each basic inspection.
• Although inspections and adjustments are performed according to the reference column procedures, if the 00-00
cause of the malfunction is discovered during basic inspection, continue the procedures as indicated in the
action column.
SHOWS INSPECTION SHOW POINTS REQUIRING
SHOWS ITEM NAMES FOR
ORDER ATTENTION BASED ON
DETAILED PROCEDURES
INSPECTION RESULTS
BASIC INSPECTION
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GENERAL INFORMATION
Using the DTC troubleshooting flow
• DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each
DTC.
DETECTION CONDITION
describes the condition
TROUBLE CONDITION under which the DTC is
detected.
DTC P0103
DTC PO103 MAF circuit high input
PCM monitors input voltage from TP sensor after ignition key is turned on. If input voltage at PCM terminal 68 is
above 8.25 V, PCM determines that TP circuit has malfunction.
MAF SENSOR
MAIN RELAY
TERMINAL D
PCM inspected
4 (01 and 05
Indicates the B
section)
inspection step 6
4 5
No. to be E 88
performed 4 6
7
(01 and 05 D 36
section)
MAF SENSOR PCM Indicates the
HARNESS SIDE CONNECTOR HARNESS SIDE CONNECTOR
connector
1P related to the
E D C B A inspection
STEP shows
the order of ACTION
troubleshooting Diagnostic procedure describes the
STEP INSPECTION ACTION appropriate
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step.
RECORDED No Record FREEZE FRAME DATA on repair order, then go
action to be taken
Has FREEZE FRAME DATA been recorded? to next step. according to
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair the result
AVAILABILITY information.
Are related Service Bulletins and/or on-line
If vehicle is not repaired, then go to next step. (Yes/No) of the
repair information available? No Go to next step. INSPECTION.
3 VERIFY CURRENT INPUT SIGNAL STATUS IS Yes Intermittent concern is existing. Go to INTERMITTENT
INSPECTION CONCERN INTERMITTENT OR CONSTANT CONCERNS TROUBLESHOOTING procedure.
Connect diagnostic tool to DLC-2. (See 01-03-33 INTERMITTENT CONCERN Reference
describes the
Start engine. TROUBLESHOOTING) item(s) to
method to Access MAF V PID using diagnostic tool. No Go to next step. perform
quickly Is MAF V PID within 0.2 - 8.3 V?
4 INSPECT POOR CONNECTION OF MAF Yes Repair or replace terminals, then go to Step 8. ACTION.
determine the SENSOR CONNECTOR
malfunctioning Turn ignition key to OFF.
part(s). Disconnect MAF sensor connector.
Check for poor connection (damaged, pulled-
out terminals, corrosion etc.).
Are there any malfunctions?
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GENERAL INFORMATION
Using the diagnostic index
• Malfunction symptoms are listed in the diagnostic index under symptom troubleshooting.
• The exact malfunction symptoms can be selected by following the index.
No. TROUBLESHOOTING ITEM DESCRIPTION Page
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GENERAL INFORMATION
Using the quick diagnosis chart
• The chart lists the relation between the symptom and the cause of the malfunction.
• The chart is effective in quickly narrowing down the relation between symptom and cause of the malfunction. It
also specifies a range of common causes when multiple malfunction symptoms occur.
• The appropriate diagnostic inspection relating to a malfunction cause as specified by the symptoms can be
selected by looking down the diagnostic inspection column of the chart.
Hydrolocked engine
Improper dipstick
Fuel quality
electrical)
installed
Troubleshooting item
9 Fast idle/runs on X
Misses Acceleration/cruise X X X
11 Acceleration/cruise/
Buck/jerk X X X
deceleration
Hesitation/stumble Acceleration X X X
Surges Acceleration/cruise X X X
13 Knocking/pinging Acceleration/cruise X X
19 Exhaust smoke X X
30 Constant voltage
31 Spark plug condition X X X X X
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GENERAL INFORMATION
Using the symptom troubleshooting
• Symptom troubleshooting shows diagnostic procedures, inspection methods, and proper action to be taken for
each trouble symptom.
DESCRIPTION
describes what 00-00
kind of TROUBLE
SYMPTOM TROUBLE SYMPTOM
14 Engine flares up or slips when upshifting or down shifting
When accelerator pedal is depressed for driveway, engine speed increase but vehicle speed increase
DESCRIPTION slowly.
When accelerator is depressed while driving, engine speed increases but vehicle not.
There is clutch slip because clutch is stuck or line pressure is low.
Clutch stuck, slippage (forward clutch, 3-4 clutch, 2-4 brake band, one-way clutch 1, one-way clutch 2)
Line pressure low
POSSIBLE Malfunction or mis-adjustment of TP sensor
CAUSE Malfunction of VSS
Malfunction of input/turbine speed sensor
describes Malfunction of sensor ground
possible Malfunction of shift solenoid A, B or C
point of Malfunction of TCC solenoid valve
POSSIBLE Malfunction of body ground
malfunction CAUSE
Malfunction of throttle cable
Malfunction of throttle valve body
Poor operating of mechanical pressure
Selector lever position disparity
TR switch position disparity
Note
STEP shows
Before following troubleshooting steps, make sure that Automatic Transaxle On-board Diagnostic and
the order of Automatic Transaxle Basic Inspection are conducted.
troubleshooting. ACTION
Diagnostic procedure describes the
STEP INSPECTION ACTION appropriate
1 Is line pressure okay? Yes Go to next step.
action to be
No Repair or replace any defective parts according to
Reference inspection results. taken according
item(s) for 2 Is shift point okay? Yes Go to next step to the result
additional (See 05-17-5 ROAD TEST) No Go to symptom troubleshooting No.9 "Abnormal shift". (Yes/No) of the
information 3 Stop engine and turn ignition switch on. Yes Overhaul control valve body and repair or replace any INSPECTION.
Connect diagnostic tool to DLC-2. defective parts.
to perform (See ATX Workshop Manual GF4A-EL (1666-1A-99F))
INSPECTION. Simulate SHIFT A, SHIFT B and SHIFT C PIDs How to
for ON.
Is operating sound of shift solenoids heard? If problem remains, replace or overhaul transaxle and
perform
repair or replace defective parts. ACTION is
(See 05-17-15 AUTOMATIC TRANSAXLE
INSPECTION REMOVEVAL/INSTALLATION)
described in
describes the the relative
method to material
No Inspect for bend, damage, corrosion or loose shown.
quickly connection if shift solenoid A, B, or C terminal on ATX.
determine the Inspect for shift solenoid mechanical stuck.
malfunctioning (See 05-17-14 Inspection of Operation)
If shift solenoids are okay, inspect for open or short Reference
part(s). circuit between PCM connector terminal A, B or C. item(s) to
4 Verify test results.
perform
If okay, return to diagnostic index to service any additional symptoms.
If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair or
ACTION.
diagnosis.
If vehicle is repaired, troubleshooting completed.
If vehicle is not repaired or additional diagnostic information is not available, replace or reprogram PCM.
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GENERAL INFORMATION
UNITS
id000000100400
Rounding Off
• Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
• The actual converted values for 2.7 kgf/cm2 are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie
WM: GENERAL INFORMATION
00-00–12
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
GENERAL INFORMATION
SERVICE CAUTIONS
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Note
• Referring to the fluorescent dye instruction manual, mix the specified amount of dye into the engine oil or
ATF (or transaxle/transmission oil).
2. Pour the fluorescent dye into the engine oil or ATF (or transaxle/transmission oil).
3. Allow the engine to run for 30 min.
4. Inspect for dye leakage by irradiating with UV light (black light), and identify the type of oil that is leaking.
5. If no dye leakage is found, allow the engine to run for another 30 min. or drive the vehicle then reinspect.
6. Find where the oil is leaking from, then make necessary repairs.
Note
• To determine whether it is necessary to replace the oil after adding the fluorescent dye, refer to the
fluorescent dye instruction manual.
LEAKED OIL
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Removal of Parts
• While correcting a problem, also try to determine
its cause. Begin work only after first learning
which parts and sub-components must be
removed and disassembled for replacement or
repair. After removing the part, plug all holes and
ports to prevent foreign material from entering.
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GENERAL INFORMATION
Disassembly
• If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance, and
identified so that reassembly can be performed 00-00
easily and efficiently.
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Arrangement of Parts
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
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Cleaning of Parts
• All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning
• Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
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GENERAL INFORMATION
Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, these parts should be replaced with
new ones:
— Oil seals
— Gaskets
— O-rings
— Lock washers
— Cotter pins
— Nylon nuts
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• Depending on location:
— Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
— Oil should be applied to the moving
components of parts.
— Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
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Adjustment
• Use suitable gauges and testers when making
adjustments.
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GENERAL INFORMATION
Hose Clamps
• When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
00-00
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Torque Formulas
• When using a torque wrench-SST or equivalent
combination, the specified torque must be SST
recalculated due to the extra length that the SST
3
or equivalent adds to the torque wrench.
2
1
Recalculate the torque by using the following
0
formulas. Choose the formula that applies to you.
1
2
3
Torque Unit Formula
N·m N·m × [L/(L+A)]
kgf·m kgf·m × [L/(L+A)]
kgf·cm kgf·cm × [L/(L+A)] A L
ft·lbf ft·lbf × [L/(L+A)]
acxuuw00000019
in·lbf in·lbf × [L/(L+A)]
Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
PROTECTIVE PLATES
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Dynamometer
• When inspecting and servicing the power train on the dynamometer or speedometer tester, pay attention to the
following:
— Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.
— Make sure the vehicle is in a facility with an exhaust gas ventilation system.
— Since the rear bumper might deform from the heat, cool the rear with a fan. (Surface of the bumper must be
below70°C {158°F} degrees.)
— Keep the area around the vehicle uncluttered so that heat does not build up.
— Watch the water temperature gauge and do not overheat the engine.
— Avoid added load to the engine and maintain normal driving conditions as much as possible.
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GENERAL INFORMATION
Note
• When only the front or rear wheels are rotated on a chassis dynamometer or equivalent, the DSC CM
determines that there is a malfunction in the DSC and illuminates the following lights:
— ABS warning light
— Brake system warning light
— DSC indicator light
• If the above lights are illuminated, dismount the vehicle from the chassis dynamometer and turn the
ignition switch to the LOCK position. Then, turn the ignition switch back to the ON position, run the vehicle
at 10 km/h or more and verify that the warning lights go out. In this case, a DTC will be stored in the
memory. Clear the DTC from the memory by following the memory clearing procedure [DSC] in the on-
board diagnostic system. (See04-02-3 ON-BOARD DIAGNOSIS.)
AWD inspection/service
Speedometer tester measurement
Caution
• Install the tension bar (chain wire) to the tie down hook and secure the vehicle to prevent it from
rolling and running off.
• Do not accelerate suddenly from a standstill or accelerate/decelerate rapidly.
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GENERAL INFORMATION
Wheel balancer (on the vehicle balancer)
1. Jack up all four wheels.
2. Support the wheels (front or rear) on the side to be measured (near the wheels) using a wheel balancer sensor
stand.
3. Support the wheels on the side not to be
measured (near the wheels) using safety stands. 00-00
4. Set up the wheel balancer and rotate the wheels
using engine drive to measure the wheel balance.
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SST
• Some global SST or equivalent are used as SSTs necessary for vehicle repair. Note that these SSTs are
marked with global SST numbers.
• Note that a global SST number is written together with a corresponding Mazda SST number as shown below.
1: 49 UN303 009
2: 303-009
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GENERAL INFORMATION
INSTALLATION OF RADIO SYSTEM
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• If a radio system is installed improperly or if a high-powered type system is used, the CIS and other systems
may be affected. When the vehicle is to be equipped with a radio, observe the following precautions:
— Install the antenna at the farthest point from control modules.
— Install the antenna feeder as far as possible from the control module wiring harnesses.
— Ensure that the antenna and feeder are properly adjusted.
— Do not install a high-powered radio system.
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ELECTRICAL SYSTEM
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Electrical Parts
Battery cable
• Before disconnecting connectors or removing
electrical parts, disconnect the negative battery
BATTERY CABLE
cable.
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Wiring Harness
• To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using a
flathead screwdriver.
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Caution
• Do not remove the wiring harness
protective tape. Otherwise, the wires NO GOOD
could rub against the body, which could
result in water penetration and electrical
shorting.
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GENERAL INFORMATION
Connectors
Disconnecting connectors
• When disconnecting a connector, grasp the
connectors, not the wires. GOOD NO GOOD
00-00
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Locking connector
• When locking connectors, listen for a click
indicating they are securely locked.
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GENERAL INFORMATION
Inspection
Caution
• To prevent damage to the terminal, wrap a thin wire around the tester probe before inserting into
terminal.
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Terminals
Inspection
• Pull lightly on individual wires to verify that they
are secured in the terminal.
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GENERAL INFORMATION
Replacement
• Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it
locks securely.
• Insert a thin piece of metal from the terminal side
of the connector and with the terminal locking tab
pressed down, pull the terminal out from the 00-00
TYPE A
connector.
TYPE B
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Wiring Harness
Wiring color codes
• Two-color wires are indicated by a two-color code symbol.
• The first letter indicates the base color of the wire
and the second is the color of the stripe.
CODE COLOR CODE COLOR B/R BR/Y
B Black O Orange
BR Brown P Pink BLACK BROWN
G Green R Red
GY Gray V Violet
L Blue W White
LB Light Blue Y Yellow RED YELLOW
LG Light Green – –
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GENERAL INFORMATION
Fuse
Replacement
• When replacing a fuse, be sure to replace it with one of the same capacity. If a fuse malfunctions again, the
circuit probably has a short and the wiring should be inspected.
• Be sure the negative battery terminal is disconnected before replacing a main fuse.
• When replacing a pullout fuse, use the fuse puller.
PULLER
FUSE
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Part-side connector
The viewing orientation for part-side connectors is
from the terminal side. PART NAME*
* : Part names are shown only when there are
PCM
multiple connector drawings.
VIEWING
CONNECTOR ORIENTATION
SYMBOL
PART
VIEWING ORIENTATION
PART-SIDE CONNECTOR
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VIEWING
CONNECTOR ORIENTATION
SYMBOL
VEHICLE WIRING
HARNESS-SIDE
CONNECTOR VIEWING ORIENTATION
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GENERAL INFORMATION
Other
When it is necessary to show the terminal side of the
vehicle wiring harness-side connectors, such as the
following connectors, the viewing orientation is from DLC-2
the terminal side.
• Main fuse block and the main fuse block relays 00-00
• Data link connector
• Check connector
• Relay box
CONNECTOR
VIEWING
ORIENTATION
SYMBOL
acxuuw00000474
Caution
• Do not connect a jumper wire from the power source line to a body ground. This may cause
burning or other damage to wiring harnesses or electronic components.
acxuuw00000468
Voltmeter
• The DC voltmeter is used to measure circuit POWER SOURCE LINE
voltage. A voltmeter with a range of 15 V or more
is used by connecting the positive (+) probe
(red lead wire) to the point where voltage will
be measured and the negative (-) probe (black BLACK LEAD - V +
lead wire) to a body ground.
RED LEAD
acxuuw00000469
00-00–25
1871-1U-06B(00-00).fm 26 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
Ohmmeter
Caution
• Do not connect the ohmmeter to any circuit where voltage is applied. This will damage the
ohmmeter.
GROUND LINE
- Ω +
acxuuw00000470
acxuuw00000451
GROUND
acxuuw00000471
00-00–26
1871-1U-06B(00-00).fm 27 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITIONS
id000000800500
Jacking Positions
Warning
• Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious 00-00
injury. Use only the correct front and rear jacking points and block the wheels.
• Use safety stands to support the vehicle after it has been lifted.
Front
Note
• To prevent obstruction between the jack body and front bumper when the jack body is inserted, use a low-
floor type jack (frame height is 170 mm or less).
acxuuw00000066
Rear
2WD
• Near the center of the rear crossmember.
acxuuw00000064
AWD
• At the center of the rear differential.
acxuuw00000065
00-00–27
1871-1U-06B(00-00).fm 28 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
Vehicle Lift Positions
Front and rear
Warning
• Lifting a vehicle that is not stabilized is dangerous. The vehicle can slip off the lift and cause
serious injury and/or vehicle damage. Make sure that the vehicle is on the lift horizontally by
adjusting the height of the support at the end of the arm of the lift.
Note
• The arrow at the rear of the vehicle indicates that it is the same as the illustration for the front of the
vehicle.
acxuuw00000068
Note
• The arrow at the rear of the vehicle indicates that it is the same as the illustration for the front of the
vehicle.
acxuuw00000069
00-00–28
1871-1U-06B(00-00).fm 29 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
TOWING
id000000800600
• Proper lifting and towing are necessary to prevent damage to the vehicle.
Particularly when towing a AWD vehicle, where all the wheels are connected to the drive train, proper
transporting of the vehicle is absolutely essential to avoid damaging the drive system. Government and local
laws must be followed. 00-00
• A towed 2WD vehicle should have its front wheels off the ground. If excessive damage or other conditions
prevent this, use wheel dollies.
• When towing a 2WD vehicle with the rear wheels on the ground, release the parking brake.
• A towed AWD vehicle must have all its wheels off
the ground.
WHEEL DOLLIES
acxuuw00000512
Caution
• Don't tow with sling-type equipment. This
could damage the vehicle. Use wheel-lift
or flatbed equipment.
acxuuw00000513
Caution
• Don't tow the vehicle pointed backward
with driving wheels on the ground. This
may cause internal damage to the
transaxle.
acxuuw00000514
00-00–29
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GENERAL INFORMATION
Towing a AWD Vehicle
Warning
• Towing a AWD vehicle with either the
front or rear wheels on the ground is
dangerous as the drive train could be
damaged, or the vehicle could trail away
from the tow truck and cause an
accident. Always tow a AWD vehicle with
all four wheels off the ground. If the drive
train has been damaged, transport the
vehicle on a flat bed truck.
acxuuw00000515
Towing/Tiedown Hooks
Caution
• Don't use the tiedown hooks under the front and rear for towing. They are designed ONLY for tying
down the vehicle when it's being transported. Using them for towing will damage the bumper.
Tiedown Hooks
1. Remove the tiedown eyelet, lug wrench, and jack lever from the trunk.
2. Wrap a screwdriver or similar tool with a soft cloth
to prevent damage to the bumper and open the
cap located on the front and rear bumper.
Caution
• The cap cannot be completely removed.
Do not use excessive force as it may
damage the cap or scratch the painted
bumper surface.
acxuuw00000516
acxuuw00000517
acxuuw00000518
00-00–30
1871-1U-06B(00-00).fm 31 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
4. Hook the tying rope to the tiedown eyelet.
00-00
acxuuw00000519
acxuuw00000520
Caution
• If the tiedown eyelet is not securely tightened, it may loosen or disengage from the bumper when
tying down the vehicle. Make sure that the tiedown eyelet is securely tightened to the bumper.
End Of Sie
TIEDOWN HOOK
id000000800700
Caution
• Do not use the tie down hook for towing the vehicle. Use it only for securing the vehicle.
Front
FRONT
acxuuw00000395
Rear
End Of Sie
REAR
acxuuw00000396
00-00–31
1871-1U-06B(00-00).fm 32 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
IDENTIFICATION NUMBER LOCATIONS
id000000800800
Vehicle Identification Number (VIN)
acxuuw00002317
acxuuw00000346
00-00–32
1871-1U-06B(00-00).fm 33 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
SAE STANDARDS
id000000800900
• In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations
are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda
manuals up to now and their SAE equivalents.
SAE Standard SAE Standard 00-00
Remark Remark
Abbreviation Name Abbreviation Name
AP Accelerator Pedal MAP Manifold Absolute Pressure
APP Accelerator Pedal Position MAF sensor Mass Air Flow Sensor
ACL Air Cleaner MFL Multiport Fuel Injection
A/C Air Conditioning OBD On-board Diagnostic System
BARO Barometric Pressure OL Open Loop
B+ Battery Positive Voltage OC Oxidation Catalytic Converter
CMP sensor Camshaft Position Sensor O2S Oxygen sensor
CAC Charge Air Cooler PNP Park/Neutral Position
CLS Closed Loop System PSP Power Steering Pressure
CTP Closed Throttle Position PCM Powertrain Control Module #3
CPP Clutch Pedal Position Pulsed
PAIR Pulsed Secondary Air Injection
CIS Continuous Fuel Injection System injection
CKP sensor Crankshaft Position Sensor Injection
DLC Data Link Connector AIR Secondary Air Injection with air
DTM Diagnostic Test Mode #1 pump
DTC Diagnostic Test Code(s) SAPV Secondary Air Pulse Valve
DI Distributor Ignition Sequential Multiport Fuel
SFI
DLI Distributorless Ignition Injection
EI Electronic Ignition #2 3GR Third Gear
ECT Engine Coolant Temperature TWC Three Way Catalytic Converter
EM Engine Modification TB Throttle Body
EVAP Evaporative Emission TP sensor Throttle Position Sensor
EGR Exhaust Gas Recirculation TCC Torque Converter Clutch
FC Fan Control Transmission (Transaxle) Control
TCM
FF Flexible Fuel Module
4GR Fourth Gear TR Transmission (Transaxle) Range
GEN Generator TC Turbocharger
GND Ground VSS Vehicle Speed Sensor
With VR Voltage Regulator
HO2S Heated Oxygen Sensor
heater VAF sensor Volume Air Flow Sensor
IAC Idle Air Control Warm Up Three Way Catalytic
WU-TWC #4
IAT Intake Air Temperature Converter
KS Knock Sensor WOP Wide Open Throttle
MIL Malfunction Indicator Lamp
00-00–33
1871-1U-06B(00-00).fm 34 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
ABBREVIATIONS
id000000801000
End Of Sie
00-00–34
1871-1U-06B(00-00).fm 35 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
PRE-DELIVERY INSPECTION
id000000801100
Pre-Delivery Inspection Table
Exterior
INSPECT and ADJUST, if necessary, the following items to specification:
❏ Glass, exterior bright metal and paint for damage 00-00
❏ Wheel lug nuts
❏ All weatherstrips for damage or detachment
❏ Tire pressures
❏ Headlight cleaner and fluid level (if equipped)
❏ Operation of hood release and lock
❏ Operation of fuel-filler lid opener
❏ Door operation and alignment including side door and back door
❏ Headlight aiming
INSTALL the following parts:
❏ Flap (front)
❏ Wheel caps or rings (if equipped)
Interior
INSTALL the following items:
❏ Fuse for accessories
INSPECT the operations of the following items:
❏ Seat controls (slide and recline) and headrests
❏ Folding rear seat
❏ Door locks, including childproof door locks
❏ Seat belts and warning system
❏ Ignition switch and steering lock
❏ Transaxle range switch
❏ Warning buzzers
❏ Ignition key reminder alarm
❏ Air bag system using warning light
❏ Cruise control system (if equipped)
❏ Power door lock
❏ Shift-lock system (if equipped)
❏ Starter interlock
❏ All lights including warning, and indicator lights
❏ Horn, wipers, and washers
❏ Wiper blades performance
Clean wiper blades and windshield, if necessary
❏ Antenna
❏ Audio system
❏ Cigarette lighter and clock
❏ Power windows (if equipped)
❏ Heater, defroster, and air conditioner at various mode selections (if equipped)
INSPECT the following items:
❏ Presence of spare fuse
❏ Upholstery and interior finish
INSPECT and ADJUST, if necessary, the following items:
❏ Operation and fit of windows
❏ Parking brake
00-00–35
1871-1U-06B(00-00).fm 36 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
Under hood— engine running at operating temperature
INSPECT the following items:
❏ Automatic transaxle fluid level
❏ Operation of idle-up system for electrical load, air conditioner or power steering (if equipped)
❏ Ignition timing
❏ Idle speed
❏ Operation of throttle position sensor
❏ Operation of EGR valve
On hoist
INSPECT the following items:
❏ Underside fuel, coolant and hydraulic lines, fittings, connections, and components for leaks
❏ Tires for cuts or bruises
❏ Steering linkage, suspension, exhaust system, and all underside hardware for looseness or damage
Road test
INSPECT the following items:
❏ Brake operation
❏ Steering control
❏ Operation of gauges
❏ Squeaks, rattles, and unusual noises
❏ Engine general performance
❏ Emergency locking retractors and automatic locking retractors
❏ Cruise control system (if equipped)
❏ Operation of meters and gauges, squeaks, rattles, and abnormal noises
00-00–36
1871-1U-06B(00-00).fm 37 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
SCHEDULED MAINTENANCE
id000000801200
Scheduled Maintenance Table for U.S.A., CANADA and Puerto Rico
Schedule 1: (Normal Driving Conditions) for U.S.A.
• The vehicle is mainly operated where none of the “unique driving conditions” apply.
• For CANADA and Puerto Rico, follow schedule 2. 00-00
Number of months or kilometers (miles), whichever comes first
Months 6 12 18 24 30 36 42 48
Maintenance Interval
× 1000 km 12 24 36 48 60 72 84 96
× 1000 miles 7.5 15 22.5 30 37.5 45 52.5 60
ENGINE
Audible inspect every 120,000 km (75,000 miles),
Engine valve clearance
if noisy, adjust
Drive belts (tension) I
Engine oil R R R R R R R R
Engine oil filter R R R R R R R R
COOLING SYSTEM
Replace at first 192,000 km (120,000 miles) or 10 years;
FL22 type*1 after that, every 96,000 km (60,000 miles) or 5 years
Engine coolant
Replace at first 96,000 km (60,000 miles) or 4 years; after
Others
that, every 2 years
FUEL SYSTEM
Air cleaner element R
Fuel lines and hoses*2 I I
*2 I
Hoses and tubes for emission
IGNITION SYSTEM
Spark plugs Replace every 120,000 km (75,000 miles)
CHASSIS and BODY
Brake lines, hoses and connections I I
Disc brakes I I I I
Tire (Rotation) Rotate every 12,000 km (7,500 miles)
Steering operation and linkages I I
Front and rear suspension and ball joints I I
Rear differential oil *3*4
Transfer oil *4
Chart symbols:
I: Inspect and repair, clean, adjust, or replace if necessary.
R: Replace
L: Lubricate
Remarks
• After the prescribed period, continue to follow the described maintenance at the recommended intervals.
• Refer below for a description of items marked* in the maintenance chart.
*1: Use FL22 type coolant in vehicles with the inscription “FL22” on the radiator cap itself or the surrounding
area. Use FL22 when replacing the coolant.
*2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not
void your emissions warranties. However, Mazda recommends that all maintenance services be performed
at the recommended time or mileage/kilometer period to ensure long-term reliability.
*
3: If the vehicle is operated primarily under any of the following conditions, replace the rear differential oil every
45,000 km (28,100 miles).
a. Towing a trailer or using a car - top carrier
b. Driving in dusty, sandy or wet condition
c. Extended periods of idling or low speed operation
d. Repeated short trips of less than 16 km (10 miles)
*
4: If this component has been submerged in water, the oil should be replaced.
00-00–37
1871-1U-06B(00-00).fm 38 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
Schedule 2: CANADA, Puerto Rico and (Unique Driving Conditions) for U.S.A.
• Repeated short-distance driving
• Driving in dusty conditions
• Driving with extended use of brakes
• Driving in areas where salt or other corrosive materials are used
• Driving on rough or muddy roads
• Extended periods of idling or low-speed operation
• Driving for long periods in cold temperatures or extremely humid climates
Number of months or kilometers (miles), whichever comes first
Months 4 8 12 16 20 24 28 32 36 40 44 48
Maintenance Interval
× 1000 km 8 16 24 32 40 48 56 64 72 80 88 96
× 1000 miles 5 10 15 20 25 30 35 40 45 50 55 60
ENGINE
Engine valve clearance Audible inspect every 120,000 km (75,000 miles), if noisy, adjust
Drive belts (tension) I
Puerto Rico Replace every 5,000 km (3,000 miles) or 3 months
Engine oil
Others R R R R R R R R R R R R
Engine oil filter R R R R R R R R R R R R
COOLING SYSTEM
Replace at first 192,000 km (120,000 miles) or 10 years;
FL22 type*1 after that, every 96,000 km (60,000 miles) or 5 years
Engine coolant
Replace at first 96,000 km (60,000 miles) or 4 years;
Others
after that, every 2 years
Engine coolant level I I I I I I I I I I I I
FUEL SYSTEM
Puerto Rico R R
Air cleaner element
Others R
Fuel lines and hoses*2 I I
*2 I
Hoses and tubes for emission
IGNITION SYSTEM
U.S.A. Replace every 96,000 km (60,000 miles)
Spark plugs
Others*3 Replace every 120,000 km (75,000 miles)
ELECTRICAL SYSTEM
Function of all lights I I I I I I I I I I I I
CHASSIS and BODY
Brake lines, hoses and connections I I
Brake fluid level I I I I I I I I I I I I
Disc brakes I I I I
Tire (Rotation) Rotate every 8,000 km (5,000 miles)
Tire inflation pressure and tire wear I I I I I I I I I I I I
Steering operation and linkages I I
Power steering fluid level I I I I I I I I I I I I
Front and rear suspension and ball joints I I
Rear differential oil *4*5
Transfer oil *5
Chart symbols:
I: Inspect and repair, clean, adjust, or replace if necessary.
R: Replace
L: Lubricate
00-00–38
1871-1U-06B(00-00).fm 39 ページ 2006年3月15日 水曜日 午前10時29分
GENERAL INFORMATION
Remarks
• After the prescribed period, continue to follow the described maintenance at the recommended intervals.
• Refer below for a description of items marked* in the maintenance chart.
*1: Use FL22 type coolant in vehicles with the inscription “FL22” on the radiator cap itself or the surrounding
area. Use FL22 when replacing the coolant.
*2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not 00-00
void your emissions warranties. However, Mazda recommends that all maintenance services be performed
at the recommended time or mileage/kilometer period to ensure long-term reliability.
*3: If the vehicle is operated primarily under any of the following conditions, replace the spark plugs every
96,000 km (60,000 miles) or shorter.
a. Repeated short-distance driving
b. Extended periods of idling or low-speed operation
c. Driving for long periods in cold temperatures or extremely humid climates
*4: If the vehicle is operated primarily under any of the following conditions, replace the rear differential oil every
45,000 km (28,100 miles).
a. Towing a trailer or using a car - top carrier
b. Driving in dusty, sandy or wet condition
c. Extended periods of idling or low speed operation
d. Repeated short trips of less than 16 km (10 miles)
*
5: If this component has been submerged in water, the oil should be replaced.
End Of Sie
00-00–39
1871-1U-06B(01-02).fm 1 ページ 2006年3月15日 水曜日 午前10時32分
ENGINE 01SECTION
01-02
Toc of SCT
ON-BOARD DIAGNOSTIC EMISSION SYSTEM
[L3 WITH TC] . . . . . . . . . . . . . 01-02 [L3 WITH TC] . . . . . . . . . . . . . 01-16
SYMPTOM TROUBLESHOOTING CHARGING SYSTEM
[L3 WITH TC] . . . . . . . . . . . . . 01-03 [L3 WITH TC] . . . . . . . . . . . . . 01-17
MECHANICAL IGNITION SYSTEM
[L3 WITH TC] . . . . . . . . . . . . . 01-10 [L3 WITH TC] . . . . . . . . . . . . . 01-18
LUBRICATION STARTING SYSTEM
[L3 WITH TC] . . . . . . . . . . . . . 01-11 [L3 WITH TC] . . . . . . . . . . . . . 01-19
COOLING SYSTEM CRUISE CONTROL SYSTEM
[L3 WITH TC] . . . . . . . . . . . . . 01-12 [L3 WITH TC] . . . . . . . . . . . . . 01-20
INTAKE-AIR SYSTEM CONTROL SYSTEM
[L3 WITH TC] . . . . . . . . . . . . . 01-13 [L3 WITH TC] . . . . . . . . . . . . . 01-40
FUEL SYSTEM TECHNICAL DATA
[L3 WITH TC] . . . . . . . . . . . . . 01-14 [L3 WITH TC] . . . . . . . . . . . . . 01-50
EXHAUST SYSTEM SERVICE TOOLS
[L3 WITH TC] . . . . . . . . . . . . . 01-15 [L3 WITH TC] . . . . . . . . . . . . . 01-60
Toc of SCT
01-02 ON-BOARD DIAGNOSTIC [L3 WITH TC]
ON-BOARD DIAGNOSTIC Diagnostic Monitoring Test Results
WIRING DIAGRAM[L3 WITH TC] . . . . . 01-02–3 Access Procedure . . . . . . . . . . . . . . . 01-02–8
MONITORING SYSTEM AND CONTROL Simulation Function Procedure . . . . . . 01-02–9
SYSTEM DEVICE RELATIONSHIP DIAGNOSTIC MONITORING TEST
CHART[L3 WITH TC] . . . . . . . . . . . . . . 01-02–5 RESULTS[L3 WITH TC] . . . . . . . . . . . . 01-02–9
FOREWORD[L3 WITH TC] . . . . . . . . . . . 01-02–6 AFTER REPAIR PROCEDURE
OBD-II PENDING TROUBLE CODE [L3 WITH TC]. . . . . . . . . . . . . . . . . . . . . 01-02–10
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-02–6 KOEO/KOER SELF TEST
OBD-II FREEZE FRAME DATA [L3 WITH TC]. . . . . . . . . . . . . . . . . . . . . 01-02–10
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-02–6 OBD-II DRIVE MODE
OBD-II ON-BOARD SYSTEM [L3 WITH TC]. . . . . . . . . . . . . . . . . . . . . 01-02–10
READINESS TEST[L3 WITH TC] . . . . . 01-02–6 EGR System Repair Verification
OBD-II READ/CLEAR DIAGNOSTIC TEST Drive Mode . . . . . . . . . . . . . . . . . . . . 01-02–11
RESULTS[L3 WITH TC] . . . . . . . . . . . . . 01-02–6 HO2S heater, HO2S, and TWC
OBD-II PARAMETER IDENTIFICATION Repair Verification Drive Mode. . . . . . 01-02–11
(PID) ACCESS[L3 WITH TC] . . . . . . . . 01-02–6 EVAP System Repair Verification
OBD-II DIAGNOSTIC MONITORING TEST Drive Mode . . . . . . . . . . . . . . . . . . . . 01-02–12
RESULTS[L3 WITH TC] . . . . . . . . . . . . . 01-02–7 PCM Adaptive Memory Production,
ON-BOARD DIAGNOSTIC TEST EGR, HO2S heater, HO2S, TWC,
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-02–7 and EVAP System Repair Verification
DTC Reading Procedure. . . . . . . . . . . . 01-02–7 Drive Mode . . . . . . . . . . . . . . . . . . . . 01-02–12
Pending Trouble Code DTC TABLE[L3 WITH TC]. . . . . . . . . . . . 01-02–13
Access Procedure . . . . . . . . . . . . . . . . 01-02–7 DTC B1342[L3 WITH TC] . . . . . . . . . . . . 01-02–21
Freeze Frame PID Data DTC P0011[L3 WITH TC] . . . . . . . . . . . . 01-02–22
Access Procedure . . . . . . . . . . . . . . . 01-02–7 DTC P0012[L3 WITH TC] . . . . . . . . . . . . 01-02–23
On-Board System Readiness Tests DTC P0016[L3 WITH TC] . . . . . . . . . . . . 01-02–25
Access Procedure . . . . . . . . . . . . . . . 01-02–8 DTC P0030[L3 WITH TC] . . . . . . . . . . . . 01-02–26
PID/DATA Monitor and DTC P0031[L3 WITH TC] . . . . . . . . . . . . 01-02–28
Record Procedure . . . . . . . . . . . . . . . . 01-02–8 DTC P0032[L3 WITH TC] . . . . . . . . . . . . 01-02–30
DTC P0037[L3 WITH TC] . . . . . . . . . . . . 01-02–32
01-02–1
1871-1U-06B(01-02).fm 2 ページ 2006年3月15日 水曜日 午前10時32分
End of Toc
WM: ON-BOARD DIAGNOSTIC (ENGINE CONTROL SYSTEM)
01-02–2
1871-1U-06B(01-02).fm 3 ページ 2006年3月15日 水曜日 午前10時32分
c 2BG
FUEL INJECTOR
1AY
2BB NO.1
b
a 1BE FUEL INJECTOR
NO.4
2AZ
1BA 01-02
2BH
FUEL INJECTOR
1AZ NO.3
2BD
FUEL INJECTOR
NO.2
2BC
1AR 2BF
IAT SENSOR FUEL INJECTOR RELAY
1M 2BE
MAF 1AK
1AW
SENSOR
1P
2C HO2S HEATER (FRONT)
1Q
HO2S HEATER (REAR)
1AV 2D
APP 1Y
SENSOR 1AE FAN CONTROL MODULE NO.1
1U
1AC
COOLING FAN
RELAY NO.1
1AJ
PCM
1AO b
2P
FUEL PRESSURE SENSOR
2R 1R FAN CONTROL MODULE NO.2
2I
COOLING FAN
2AY RELAY NO.2
ECT SENSOR 1K
2AH
A/C RELAY b
1I
2AV
FUEL PUMP SPEED CONTROL RELAY
MAP 1AA
2AG
SENSOR
2N
BOOST AIR TEMPERATURE
FUEL PUMP RESISTOR
SENSOR 2AU
1BC
HO2S (REAR)
2Q FUEL PUMP RELAY
1H
2M b
1AT
2AD
MAIN RELAY
HO2S
(FRONT) 2AC
STARTER RELAY c
2Z 1B
IGNITION
2Y
SWITCH
DRIVE-BY-WIRE-RELAY
2X
1BF
CKP SENSOR
2W 1AX
BATTERY
CMP SENSOR 2S
f a
d e
acxuuw00002269
01-02–3
1871-1U-06B(01-02).fm 4 ページ 2006年3月15日 水曜日 午前10時32分
d e f
EGR VALVE
2AQ
2AM
2V
KS
2U 2AR
2AN
2AK
2AP
EVAP SYSTEM LEAK
DETECTION PUMP
TP SENSOR
2AL 1V
b
2AO 1AS
2E
REFRIGERANT PRESSURE SWITCH (HIGH, LOW)
1AU 2B
THROTTLE
REFRIGERANT PRESSURE SWITCH (MIDDLE) 2A
ACTUATOR
1J
2F
PSP SWITCH SPILL VALVE CONTROL
2T
2G
SOLENOID VALVE
2H
1BB
1AQ
1BD
1BH
2AI GENERATOR
acxuuw00002270
End Of Sie
01-02–4
1871-1U-06B(01-02).fm 5 ページ 2006年3月15日 水曜日 午前10時32分
×: Applicable
Catalyst monitor
Misfire monitor
Input
Battery x x x
Ignition switch x x x
A/C switch, refrigerant pressure switch (high, low pressure) x x
TP sensor x x x x x x
ECT sensor x x x x x x x x
IAT sensor x x x x x x
MAF sensor x x x x x x x
HO2S (front) x x x x
HO2S (rear) x x x x
Fuel gauge sender unit x
BARO sensor x x
MAP sensor x
CMP sensor x
CKP sensor x x x x x x x x
VSS x x x x
Output
Fuel injector x
HO2S heater (front) x
HO2S heater (rear) x
EGR valve x
Purge solenoid valve x x x x
EVAP system leak detection pump x
MIL x x x x x x x x
DLC-2 x x x x x x x x
End Of Sie
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CUSTOMER ARRIVES
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01-02–7
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Note
• The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the PCM.
Therefore, an output device malfunction is not directly indicated as a malfunction of the monitored value
for the output device. If a monitored value of an output device is out of specification, inspect the monitored
value of the input device related to the output control.
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End Of Sie
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acxuuw00001892
Caution
• While performing the Drive Mode, always operate the vehicle in a safe and lawful manner.
• When the M-MDS is used to observe monitor system status while driving, be sure to have another
technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD
function and inspect later.
Note
• Vehicle speed and engine speed detected by the PCM may differ from that indicated by the speedometer
and tachometer. Use the M-MDS to monitor vehicle speed.
• If the OBD-II system inspection is not completed during the Drive Mode, the following causes are
considered:
— The OBD-II system detects the malfunction.
— The Drive Mode procedure is not completed correctly.
• Disconnecting the battery will reset the memory. Do not disconnect the battery during and after Drive
Mode.
• The M-MDS can be used at anytime through the course of the Drive Mode to monitor the completion
status. Monitoring can be done by viewing the ON BOARD SYSTEM READINESS menu.
• The OBD monitoring status can be confirmed with the ignition switch operation. During KOEO, the MIL
illuminates for a fail-light inspection for approx. 17 s. The OBD monitoring status is confirmed after the
fail-light inspection.
— If all of the diagnosis is completed even one time, the MIL will continue to illuminate.
— If all of the diagnosis is not completed, the MIL flashes for approx. 7 s, and then it illuminates until the
engine is started.
01-02–10
1871-1U-06B(01-02).fm 11 ページ 2006年3月15日 水曜日 午前10時32分
VEHICLE SPEED
items change from non-completed to MORE
completed. THAN 60 s
• If not completed, turn the ignition switch off
then repeat from Step 3.
5. Access DIAGNOSTIC MONITORING TEST
RESULTS menu of GENERIC OBD-II
FUNCTIONS to verify the monitor results.
• If detected values are not within specification,
repair has not been completed. IDLE
6. Verify no DTCs are available.
START TIME
ENGINE
acxuuw00001894
APPROX. 10 s
*:10 TIMES
0
1 min 3 min TIME
ABOVE 5 min
START ENGINE *: Decelerate for approx. 10 s by engine braking only while driving with an
vehicle speed of around 80 km/h (50 mph) for approx. 10 s
acxuuw00001895
4. Stop the vehicle and access ON BOARD SYSTEM READINESS menu of GENERIC OBD-II FUNCTION to
verify the OBD monitoring status.
• If completed, the OBD monitoring status items change from non-completed to completed.
• If not completed, turn the ignition switch off then repeat from Step 3.
5. Access DIAGNOSTIC MONITORING TEST RESULTS menu of GENERIC OBD-II FUNCTIONS to verify the
monitor results.
• If detected values are not within the specification, repair has not been completed.
6. Verify no DTCs are available.
01-02–11
1871-1U-06B(01-02).fm 12 ページ 2006年3月15日 水曜日 午前10時32分
Note
• If “EVAP System Repair Verification Drive Mode” cannot be performed (it is impossible to drive the vehicle
under this drive mode condition), perform the EVAP system test procedure as an alternative.
1. Verify that all of the following PIDs are within the following specifications. All PIDs must be within specifications
before the engine is started to initiate the EVAP system test.
• BARO: above 72.2 kPa {542 mmHg, 21.3 inHg}
• IAT: 5— 35 °C {41— 95 °F}
• FTL: 15— 85%
• B+: above 10.9 V
2. Clear the DTC from the PCM memory using the M-MDS.
3. Turn the ignition switch off.
4. Leave the vehicle for 5 hours or more.
5. Start the engine and idle it for more than 5 min.
6. Drive the vehicle at an engine speed of 65— 80 km/h {40— 50 mph} for more than 5 min.
7. Stop the vehicle and the turn ignition switch off.
8. Leave vehicle as it is for 5.5 hours or more.
9. Start the engine.
10. Access the ON BOARD SYSTEM READINESS to verify the OBD monitoring status.
• If completed, the OBD monitoring status items change from non-completed to completed.
• If not completed, turn the ignition switch off then go back to Step 1.
11. Access the DIAGNOSTIC MONITORING TEST RESULTS to verify the monitor results.
• If detected values are not within specification, the repair has not been completed.
12. Verify that no DTCs are present.
PCM Adaptive Memory Production, EGR, HO2S heater, HO2S, TWC, and EVAP System Repair Verification
Drive Mode
1. Start the engine and warm it up completely.
2. Clear the DTC from the PCM memory using the M-MDS.
3. Verify the following conditions and correct if necessary:
• All accessory loads (A/C, headlights, blower fan, rear window defroster) are off.
4. Verify that all of the following PIDs are within the following specifications. All PIDs must be within specifications
from Step 5 to 6.
• BARO: above 72.2 kPa {542 mmHg, 21.3 inHg}
• IAT: 5— 35 °C {41— 95 °F}
• FTL: 15— 85%
• B+: above 10.9 V
5. With the vehicle stopped, race the engine at the engine speed indicated, and then drive the vehicle as shown in
the graph. The driving conditions before driving at constant speed are not specified. If possible, monitor RPM
PID for engine speed during this procedure.
T8
V3
V2
VEHICLE SPEED
V1
V4
T9
T3
T2 T10
T1
IDLE
TIME
T4 T5 T6 T7
START START START
ENGINE ENGINE ENGINE
STOP STOP
ENGINE ENGINE
acxuuw00002357
01-02–12
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
ON-BOARD DIAGNOSTIC [L3 WITH TC]
Engine speed Vehicle speed
Step Time Vehicle condition
(rpm) (km/h {mph})
1 Idle the engine after the cooling fan
T1: More than 10 s N3: Idle 0 {0}
has stopped
2 T2: More than 5 h 0 0 {0} Keep the ignition switch off
3 T3: More than 5 min Idle V1: 0 {0} —
4 T4: 5 min — V2: 65— 80 {40— 50} D RANGE
01-02
5 T5: 1 min — V3: 70— 78 {43— 49} D RANGE
6 T6: 1 min — V4: Above 89 {55} D RANGE
7 T7: 3 min — V5: 65— 80 {40— 50} D RANGE
8 Approx. 80 km/h
T8: Approx. 10 s — —
(50mph)
9 Decelerate by engine braking only
T9: Approx. 10 s — —
(10 times)
10 T10: More than 5.5 h 0 0 {0} Keep the ignition switch off
×: Applicable
— : Not applicable
Self-test Memory
DTC No. Condition MIL DC Monitor item Page
type*2 function
(See01-02-21
B1342 PCM malfunction OFF 1 CCM C, O × DTC B1342[L3
WITH TC].)
(See01-02-22
P0011 CMP Timing over-advanced ON 2 CCM C, R × DTC P0011[L3
WITH TC].)
(See01-02-23
P0012 CMP Timing over-retarded ON 2 CCM C, R × DTC P0012[L3
WITH TC].)
(See01-02-25
P0016 CKP-CMP correlation ON 2 CCM C × DTC P0016[L3
WITH TC].)
(See01-02-26
Front HO2S heater control circuit
P0030 ON 2 HO2S heater C, O, R × DTC P0030[L3
problem
WITH TC].)
(See01-02-28
P0031 Front HO2S heater circuit low input ON 2 HO2S heater C, O, R × DTC P0031[L3
WITH TC])
(See01-02-30
P0032 Front HO2S heater circuit high input ON 2 HO2S heater C, O, R × DTC P0032[L3
WITH TC].)
(See01-02-32
P0037 Rear HO2S heater circuit low input ON 2 HO2S heater C, O, R × DTC P0037[L3
WITH TC].)
(Se01-02-34
P0038 Rear HO2S heater circuit high input ON 2 HO2S heater C, O, R × DTC P0038[L3
WITH TC].)
(See01-02-36
Manifold absolute pressure/
P0069 ON 2 CCM C × DTC P0069[L3
atmospheric pressure correlation
WITH TC].)
01-02–14
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01-02–15
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01-02–16
1871-1U-06B(01-02).fm 17 ページ 2006年3月15日 水曜日 午前10時32分
01-02–17
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01-02–20
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
ON-BOARD DIAGNOSTIC [L3 WITH TC]
Self-test Memory
DTC No. Condition MIL DC Monitor item Page
type*2 function
(See01-02-
251 DTC
P2502 Generator terminal B circuit open OFF 1 – C, R ×
P2502[L3
WITH TC].)
(See01-02-
P2503
Generator output voltage signal no
OFF 1 Other C, R ×
252 DTC 01-02
electricity P2503[L3
WITH TC].)
(See01-02-
254 DTC
P2504 Battery overcharge OFF 1 Other C, R ×
P2504[L3
WITH TC].)
(See01-02-
PCM +BB (back-up battery) voltage 256 DTC
P2507 ON 1 CCM C, O, R ×
low P2507[L3
WITH TC].)
(See01-02-
PCM internal engine off timer 258 DTC
P2610 ON 2 CCM C ×
performance P2610[L3
WITH TC].)
Control module communication Bus
U0073 (See09-02D-7 DTC TABLE[MULTIPLEX COMMUNICATION SYSTEM])
off
U0101 CAN system communication error (See09-02D-7 DTC TABLE[MULTIPLEX COMMUNICATION SYSTEM])
U0121 Communication error to ABS HU/CM (See09-02D-7 DTC TABLE[MULTIPLEX COMMUNICATION SYSTEM])
Communication error to instrument
U0155 (See09-02D-7 DTC TABLE[MULTIPLEX COMMUNICATION SYSTEM])
cluster
End Of Sie
DTC B1342[L3 WITH TC]
WM: CRUISE CONTROL SYSTEM
id010239815700
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY CURRENT STATUS OF MALFUNCTION Yes Replace the PCM, then go to the next step.
• Clear the DTC from the PCM memory using No Go to the next step.
the M-MDS.
• Is same DTC present?
2 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
WM: DTC P00XX
01-02–21
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
ON-BOARD DIAGNOSTIC [L3 WITH TC]
DTC P0011[L3 WITH TC]
id010239801600
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY TIMING CHAIN INSTALLATION Yes Go to the next step.
• Stop the engine. No Reinstall the timing chain, then go to Step 7.
• Remove the timing chain cover.
• Is the camshaft timing mark at the correct
point?
(See 01-10-10 TIMING CHAIN REMOVAL/
INSTALLATION[L3 WITH TC].)
4 INSPECT OCV FOR MALFUNCTION Yes Go to the next step.
• Start the engine. No Replace the OCV, then go to Step 7.
• Increase the engine speed.
• Stop the engine.
• Remove the OCV.
• Inspect the position of the spool valve in the
OCV.
• Is the spool valve located at the valve retard
position?
5 INSPECT STOPPER PIN MECHANISM Yes Go to the next step.
• Remove the timing chain. No Replace the variable valve timing actuator, then go to Step
• Inspect the stopper pin. 7.
(See 01-10-27 VARIABLE VALVE TIMING
ACTUATOR INSPECTION[L3 WITH TC].)
• Is the stopper pin mechanism normal?
6 INSPECT ROTOR POSITION Yes VARIABLE VALVE TIMING MECHANISM IS NORMAL
• Remove the variable valve timing actuator.
• Is the rotor position at the maximum valve Note
timing retard? • This DTC is detected as an intermittent concern.
• The intermittent concern might be removed using the
cleaning mode of the variable valve timing control
function.
End Of Sie
DTC P0012[L3 WITH TC]
id010239801700
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting procedure.
STORED DTCS (See 01-02-188 DTC P2088[L3 WITH TC] or 01-02-190
• Is DTC P2088 or P2089 present? DTC P2089[L3 WITH TC].)
No Go to the next step.
4 VERIFY ENGINE OIL PRESSURE Yes Inspect engine oil pressure.
• Start the engine. (See 01-11-2 OIL PRESSURE INSPECTION[L3 WITH
• Does the oil pressure warning light illuminate? TC].)
No Go to the next step.
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End Of Sie
01-02–24
1871-1U-06B(01-02).fm 25 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT CMP SENSOR CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 13.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the CMP sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
4 INSPECT CMP SENSOR FOR FOREIGN Yes Remove foreign material from the CMP sensor, then go to
MATERIAL Step 13.
• Remove the CMP sensor. No Go to the next step.
• Inspect the CMP sensor for foreign material.
• Is there any foreign material on the CMP
sensor?
5 INSPECT CMP SENSOR PULSE WHEEL Yes Replace the camshaft, then go to Step 13.
• Visually inspect the CMP sensor pulse wheel. (See01-10-20 CYLINDER HEAD GASKET
• Is there any damage or scratching to the CMP REPLACEMENT[L3 WITH TC].)
sensor pulse wheel? No Go to the next step.
6 INSPECT CMP SENSOR Yes Go to the next step.
• Inspect the CMP sensor. No Replace the CMP, then go to Step 13.
(See01-40-45 CAMSHAFT POSITION (CMP)
SENSOR INSPECTION[L3 WITH TC].)
• Is the CMP sensor normal?
7 INSPECT CKP SENSOR CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 13.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the CKP sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
01-02–25
1871-1U-06B(01-02).fm 26 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0030[L3 WITH TC]
id010239801900
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01-02–27
1871-1U-06B(01-02).fm 28 ページ 2006年3月15日 水曜日 午前10時32分
Note
• The front HO2S heater is controlled by a duty signal.
DETECTION
CONDITION
Diagnostic support note
• This is a continuous monitor (HO2S heater).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or
in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• Front HO2S heater malfunction
• Connector or terminal malfunction
• Open circuit in the wiring harness between main relay and front HO2S terminal 2B
POSSIBLE
• Short to ground in the wiring harness between main relay and front HO2S terminal 2B
CAUSE
• Open circuit in the wiring harness between front HO2S terminal 2D and PCM terminal 2C
• Short to ground in the wiring harness between front HO2S terminal 2D and PCM terminal 2C
• PCM malfunction
MAIN RELAY PCM
FRONT HO2S
PCM
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(HO2S heater related) been recorded?
01-02–28
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End Of Sie
01-02–29
1871-1U-06B(01-02).fm 30 ページ 2006年3月15日 水曜日 午前10時32分
Note
• The front HO2S heater is controlled by a duty signal.
DETECTION
CONDITION
Diagnostic support note
• This is a continuous monitor (HO2S heater).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or
in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• Front HO2S heater malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Short to power supply in the wiring harness between front HO2S terminal 2D and PCM terminal 2C
• PCM malfunction
MAIN RELAY PCM
3 6 3 5 8 7
4
2B 2D 2C
FRONT HO2S
PCM
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
01-02–30
1871-1U-06B(01-02).fm 31 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–31
1871-1U-06B(01-02).fm 32 ページ 2006年3月15日 水曜日 午前10時32分
3 5 3 4 6
C D 2D
REAR HO2S
PCM
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(HO2S heater related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–32
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End Of Sie
01-02–33
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3 6 3 7
4 5 8
C D 2D
REAR HO2S
PCM
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
01-02–34
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End Of Sie
01-02–35
1871-1U-06B(01-02).fm 36 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY STORED DTC Yes Inspect and repair DTC P0107, P0108, P2228 or P2229.
• Turn the ignition switch to off then start the No Go to the next step.
engine.
• Have DTC P0107, P0108, P2228 or P2229
been stored?
4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA No Go to troubleshooting procedures for the DTC on the
• Is DTC P0069 on the FREEZE FRAME DATA? FREEZE FRAME DATA.
5 INSPECT MAP SENSOR STUCK OPEN OR Yes Go to the next step.
CLOSED No Replace the MAP sensor, then go to step 7.
• Inspect MAP sensor. (See01-40-29 MANIFOLD ABSOLUTE PRESSURE (MAP)
(See01-40-29 MANIFOLD ABSOLUTE SENSOR/BOOST AIR TEMPERATURE SENSOR
PRESSURE (MAP) SENSOR REMOVAL/INSTALLATION[L3 WITH TC].)
INSPECTION[L3 WITH TC].)
• Is the MAP sensor normal?
6 INSPECT BARO SENSOR Yes Go to the next step.
• Inspect the BARO sensor. No Replace the PCM, then go to the next step.
(See01-40-48 BAROMETRIC PRESSURE (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
(BARO) SENSOR INSPECTION[L3 WITH TC].)
TC].)
• Is the BARO sensor normal?
7 VERIFY TROUBLESHOOTING OF DTC P0069 Yes Replace the PCM, then go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all disconnected TC].)
connectors. No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the memory using the M-
MDS.
• Start the engine.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
01-02–36
1871-1U-06B(01-02).fm 37 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT HIGH PRESSURE FUEL PUMP Yes Repair or replace the terminals, then go to Step 6.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the high pressure fuel pump
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
4 INSPECT SPILL VALVE CONTROL SOLENOID Yes Replace the high pressure fuel pump, then go to Step 6.
VALVE (See01-14-16 HIGH PRESSURE FUEL PUMP REMOVAL/
• Inspect the spill valve control solenoid valve. INSTALLATION[L3 WITH TC].)
(See01-14-19 HIGH PRESSURE FUEL No Go to the next step.
PUMP INSPECTION[L3 WITH TC].)
• Is there any malfunction?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair the terminal, then go to the next step.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion.)
• Is there any malfunction?
6 VERIFY TROUBLESHOOTING OF DTC P0089 Yes Replace the PCM, then go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all the disconnected TC].)
connectors. No Go to the next step.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–37
1871-1U-06B(01-02).fm 38 ページ 2006年3月15日 水曜日 午前10時32分
3 6 5
A 2F
3 6 5
B 2G
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related service repair information • If the vehicle is not repaired, go to the next step.
availability. No Go to the next step.
• Is any related repair information available?
01-02–38
1871-1U-06B(01-02).fm 39 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–39
1871-1U-06B(01-02).fm 40 ページ 2006年3月15日 水曜日 午前10時32分
3 4 7 6
B 2G
01-02–40
1871-1U-06B(01-02).fm 41 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–41
1871-1U-06B(01-02).fm 42 ページ 2006年3月15日 水曜日 午前10時32分
3 6
B 2N
3 6
A 2AV
01-02–42
1871-1U-06B(01-02).fm 43 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–43
1871-1U-06B(01-02).fm 44 ページ 2006年3月15日 水曜日 午前10時32分
3 6
4
B 2N
3 6
A 2AV
01-02–44
1871-1U-06B(01-02).fm 45 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–45
1871-1U-06B(01-02).fm 46 ページ 2006年3月15日 水曜日 午前10時32分
3 6
4 7
B 2N
3 6
4 7
A 2AV
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–46
1871-1U-06B(01-02).fm 47 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
WM: DTC P01XX
01-02–47
1871-1U-06B(01-02).fm 48 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY CURRENT INPUT SIGNAL STATUS IS Yes Go to the next step.
CONCERN INTERMITTENT OR CONSTANT No Intermittent concern exists. Go to INTERMITTENT
• Connect the M-MDS to DLC-2. CONCERNS TROUBLESHOOTING procedure.
• Start the engine. (See01-03-76 INTERMITTENT CONCERN
• Access the ECT, MAF, TP and RPM PIDs using TROUBLESHOOTING[L3 WITH TC])
the M-MDS.
• Warm-up the engine until the ECT PID is
above 70°C {158°F}.
• Idle engine for5 s or more.
Caution
• While driving, always operate the
vehicle in a safe and lawful manner.
01-02–48
1871-1U-06B(01-02).fm 49 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–49
1871-1U-06B(01-02).fm 50 ページ 2006年3月15日 水曜日 午前10時32分
3 4
A
3 6 7 5
C 1AK
3 5
B 1P
01-02–50
1871-1U-06B(01-02).fm 51 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–51
1871-1U-06B(01-02).fm 52 ページ 2006年3月15日 水曜日 午前10時32分
3
A
3 4 5
C 1AK
3 6 5
B 1P
01-02–52
1871-1U-06B(01-02).fm 53 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–53
1871-1U-06B(01-02).fm 54 ページ 2006年3月15日 水曜日 午前10時32分
4
C 2AU
5 6
D 2AG
6
A 2AV
01-02–54
1871-1U-06B(01-02).fm 55 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–55
1871-1U-06B(01-02).fm 56 ページ 2006年3月15日 水曜日 午前10時32分
7
3 4 6
C 2AU
7
3 4 8 6
D 2AG
3 4 5 6
A 2AV
01-02–56
1871-1U-06B(01-02).fm 57 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–57
1871-1U-06B(01-02).fm 58 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT MAF/IAT SENSOR CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 6.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the MAF/IAT sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
4 INSPECT IAT SENSOR Yes Replace MAF/IAT sensor, then go to Step 6.
• Inspect IAT sensor. No Go to the next step.
(See01-40-27 INTAKE AIR TEMPERATURE
(IAT) SENSOR INSPECTION[L3 WITH TC].)
• Is IAT sensor normal?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to the next step.
CONNECTION No Go to the next step.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
6 VERIFY TROUBLESHOOTING OF DTC P0111 Yes Replace PCM, then go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all disconnected TC].)
connectors. No Go to the next step.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine and run the engine under the
FREEZE FRAME DATA condition.
• Is PENDING CODE for this DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure“. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–58
1871-1U-06B(01-02).fm 59 ページ 2006年3月15日 水曜日 午前10時32分
3 5 6
D 1M
3 6
E 1AR
01-02–59
1871-1U-06B(01-02).fm 60 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–60
1871-1U-06B(01-02).fm 61 ページ 2006年3月15日 水曜日 午前10時32分
3 5 7 6
D 1M
3 8 6
E 1AR
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–61
1871-1U-06B(01-02).fm 62 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–62
1871-1U-06B(01-02).fm 63 ページ 2006年3月15日 水曜日 午前10時32分
3 5
A 2AH
3 5
B 2AY
PCM
ECT SENSOR WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B
B A
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to ne, then go next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ECT SENSOR CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 6.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the ECT sensor connector.
• Inspect for poor connection (damaged, pulled-
out pins, corrosion, etc.).
• Is there any malfunction?
01-02–63
1871-1U-06B(01-02).fm 64 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0117[L3 WITH TC]
id010239804000
01-02–64
1871-1U-06B(01-02).fm 65 ページ 2006年3月15日 水曜日 午前10時32分
3 5 6
A 2AH
01-02
3 6
B 2AY
PCM
ECT SENSOR WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B
B A
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(Engine cooling system related) been
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT FOR BENT TERMINALS Yes Repair or replace the terminal, then go to Step 7.
• Turn the ignition switch off. No Go to the next step.
• Disconnect the ECT sensor connector.
• Inspect ECT sensor terminals A and B (part-
side) for bending.
• Is there any malfunction?
4 CLASSIFY ECT SENSOR MALFUNCTION OR Yes Replace the ECT sensor, then go to Step 7.
WIRING HARNESS MALFUNCTION (See01-40-24 ENGINE COOLANT TEMPERATURE (ECT)
• Connect the M-MDS to DLC-2. SENSOR REMOVAL/INSTALLATION[L3 WITH TC].)
• Access the ECT PID. No Go to the next step.
• Verify the ECT value when disconnecting the
ECT sensor connector.
• Does the ECT value change?
01-02–65
1871-1U-06B(01-02).fm 66 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0118[L3 WITH TC]
id010239804100
01-02–66
1871-1U-06B(01-02).fm 67 ページ 2006年3月15日 水曜日 午前10時32分
3 5 6
A 2AH
7 01-02
3 8 6
B 2AY
PCM
ECT SENSOR WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B
B A
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(Engine cooling system related) been
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT POOR CONNECTION OF ECT Yes Repair or replace the terminal, then go to Step 9.
SENSOR CONNECTOR FOR POOR No Go to the next step.
CONNECTION
• Turn the ignition switch off.
• Disconnect ECT sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion.)
• Is there any malfunction?
4 CLASSIFY ECT SENSOR MALFUNCTION OR Yes Replace the ECT sensor, then go to Step 9.
WIRING HARNESS MALFUNCTION No Go to the next step.
• Connect the M-MDS to the DLC-2.
• Access the ECT PID.
• Connect a jumper wire between ECT sensor
terminals A and B.
• Verify the ECT value.
• Is the voltage 4.6 V or below?
01-02–67
1871-1U-06B(01-02).fm 68 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0122[L3 WITH TC]
id010239804200
01-02–68
1871-1U-06B(01-02).fm 69 ページ 2006年3月15日 水曜日 午前10時32分
4
3 5
B 2AO
01-02
3 6
A 2AK
7
D 2AP
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 CLASSIFY TP SENSOR OR HARNESS Yes Go to the next step.
MALFUNCTION No Go to step 5.
• Connect the M-MDS.
• Access the TP1 PID.
• Disconnect the throttle body connector.
• Connect a jumper wire between throttle body
terminals A and B (harness-side).
• Is the voltage above 4.9 V?
4 INSPECT TP SENSOR Yes Inspect for poor throttle body connector terminal B
• Perform the TP sensor inspection. connection. Repair or replace if necessary, then go to Step
(See01-40-32 THROTTLE POSITION (TP) 8.
SENSOR INSPECTION[L3 WITH TC].) No Replace throttle body, then go to Step 8.
• Is the TP sensor normal?
01-02–69
1871-1U-06B(01-02).fm 70 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0123[L3 WITH TC]
id010239804300
01-02–70
1871-1U-06B(01-02).fm 71 ページ 2006年3月15日 水曜日 午前10時32分
TP SENSOR NO.1
(THROTTLE BODY) PCM
5
3 4 6 8
B 2AO
01-02
3 4 9 8
A 2AK
3 4 7 8
D 2AP
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT THROTTLE BODY CONNECTOR Yes Go to the next step.
• Turn the ignition switch off. No Connect the connector securely, then go to Step 10.
• Verify that the throttle body connector is
connected securely.
• Is connector normal?
4 INSPECT THROTTLE BODY CONNECTION FOR Yes Repair or replace the suspected wiring terminal, then go to
POOR CONNECTION Step 10.
• Disconnect throttle body connector. No Go to the next step.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
5 INSPECT TP SENSOR Yes Go to the next step.
• Perform the TP sensor inspection. No Replace the throttle body, then go to Step 10.
(See01-40-32 THROTTLE POSITION (TP)
SENSOR INSPECTION[L3 WITH TC])
• Is the TP sensor normal?
01-02–71
1871-1U-06B(01-02).fm 72 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0125[L3 WITH TC]
id010239804400
01-02–72
1871-1U-06B(01-02).fm 73 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–73
1871-1U-06B(01-02).fm 74 ページ 2006年3月15日 水曜日 午前10時32分
DTC P0126
Coolant thermostat stuck open
DTC P0128
DTC P0126
• If the ECT signal never exceeds 71 °C {160 °F} after engine start for specified period, PCM determines that
the coolant thermostat is stuck open.
MONITORING CONDITIONS
— IAT: above –10 °C {14 °F}
— Vehicle speed: over 9.4 km/h {5.8 mph}
DTC P0128
• PCM monitors MAF, IAT, VSS and EAT signals and calculate radiator heat radiation ratio while following
monitoring conditions are met. If calculated value exceeds threshold, PCM determines that the coolant
thermostat is stuck open.
DETECTION MONITORING CONDITIONS
CONDITION — ECT at engine start: below 36 °C {97 °F}
— IAT: above –10 °C {14 °F}
— Difference between ECT at engine start and minimum IAT: below 6 °C {10.8 °F}
— Vehicle speed: over 32 km/h {20 mph}
Diagnostic support note
• This is an intermittent monitor (Engine cooling system).
• MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction condition during first the drive cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in PCM memory.
• DIAGNOSTIC MONITORING TEST RESULTS is available.
• ECT sensor malfunction
POSSIBLE
• Coolant thermostat malfunction
CAUSE
• PCM malfunction
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on repair order, then go to
• Have FREEZE FRAME DATA and the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(Engine cooling system related) been
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT FOR OTHER DTCS Yes Repair circuit malfunction for applicable DTCs.
• Have other DTCs been stored? No Go to the next step.
4 INSPECT COOLANT THERMOSTAT FOR Yes Inspect ECT sensor.
WHETHER STUCK OPEN Replace ECT sensor if necessary, then go to the next step.
• Perform coolant thermostat inspection. No Replace coolant thermostat, then go to the next step.
• Is coolant thermostat normal?
01-02–74
1871-1U-06B(01-02).fm 75 ページ 2006年3月15日 水曜日 午前10時32分
Note 01-02
• If workshop inside and outside
temperature difference is significant,
PCM might not operate thermostat
monitor. Therefore, it is recommended to
cool down engine out of workshop.
Note
• This test requires actual driving. Chassis
roller cannot be used for this test.
• During test drive, constant speed should
be maintained, although 2 or 3 stops
during every5 minutes of driving time
(e.g. for traffic signals) is acceptable.
Stop-and-go (e.g. in case of traffic
congestion) is not acceptable during the
test period.
• Test period depends on ECT at engine
start. (e.g. if ECT is –10°C {14°F},
monitoring period is38 minutes and
ECT is 30 °C {86 °F}, monitoring period
is 8 minutes)
01-02–75
1871-1U-06B(01-02).fm 76 ページ 2006年3月15日 水曜日 午前10時32分
Note
• This test requires actual driving. Chassis
roller cannot be used for this test.
• During test drive, constant speed should
be maintained, although 2 or 3 stops
(e.g. for traffic signals) is acceptable.
Stop-and-go (e.g. in case of traffic
congestion) is not acceptable during the
test period.
End Of Sie
DTC P0131[L3 WITH TC]
id010239804600
01-02–76
1871-1U-06B(01-02).fm 77 ページ 2006年3月15日 水曜日 午前10時32分
5 6 9 8
1C 2Z
01-02
5 6 9 8
7 1B 2AC
5 6 9 8
1A 2AD
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(HO2S related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING OR STORED DTC Yes Go to the appropriate DTC troubleshooting procedures.
• Turn the ignition switch off, then to the ON (See01-02-13 DTC TABLE[L3 WITH TC].)
position (Engine off). No Go to the next step.
• Verify the pending code or stored DTCs using
the M-MDS.
• Are other DTCs present?
4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA No Go to troubleshooting procedures for the DTC on the
• Is DTC P0131 on FREEZE FRAME DATA? FREEZE FRAME DATA.
(See01-02-13 DTC TABLE[L3 WITH TC].)
5 INSPECT FRONT HO2S CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 10.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the front HO2S connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
01-02–77
1871-1U-06B(01-02).fm 78 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–78
1871-1U-06B(01-02).fm 79 ページ 2006年3月15日 水曜日 午前10時32分
5 6 8
1C 2Z
5 6 8
7 1B 2AC
5 6 8
1A 2AD
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(HO2S related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–79
1871-1U-06B(01-02).fm 80 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–80
1871-1U-06B(01-02).fm 81 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(HO2S related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING AND STORED Yes Go to DTC P0443 troubleshooting procedures, then go to
DTC Step 14.
• Turn the ignition switch off, then to the ON No Go to the next step.
position (Engine off).
• Verify the pending or stored DTCs using the M-
MDS.
• Is DTC P0443 also present?
4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA No Go to troubleshooting procedures for DTC on FREEZE
• Is DTC P0133 on FREEZE FRAME DATA? FRAME DATA.
(See01-02-13 DTC TABLE[L3 WITH TC].)
01-02–81
1871-1U-06B(01-02).fm 82 ページ 2006年3月15日 水曜日 午前10時32分
01-02–82
1871-1U-06B(01-02).fm 83 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0134[L3 WITH TC]
id010239804900
01-02–83
1871-1U-06B(01-02).fm 84 ページ 2006年3月15日 水曜日 午前10時32分
FRONT HO2S
7
1C 2Z
7
1B 2AC
MAIN RELAY 7
1A 2AD
FRONT HO2S
PCM
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(HO2S related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING AND STORED Yes Go to the appropriate DTC troubleshooting procedures.
DTC No Go to the next step.
Note
• If fuel monitor, DTC P0132 is retrieved,
ignore it until P0134 is fixed.
01-02–84
1871-1U-06B(01-02).fm 85 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–85
1871-1U-06B(01-02).fm 86 ページ 2006年3月15日 水曜日 午前10時32分
5 6
A 2Q
B 1BC
REAR HO2S
PCM
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
01-02–86
1871-1U-06B(01-02).fm 87 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–87
1871-1U-06B(01-02).fm 88 ページ 2006年3月15日 水曜日 午前10時32分
5
A 2Q
B 1BC
REAR HO2S
PCM
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
01-02–88
1871-1U-06B(01-02).fm 89 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–89
1871-1U-06B(01-02).fm 90 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(HO2S related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY Service Information.
• Verify related Service Bulletins and/or-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–90
1871-1U-06B(01-02).fm 91 ページ 2006年3月15日 水曜日 午前10時32分
01-02–91
1871-1U-06B(01-02).fm 92 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0140[L3 WITH TC]
id010239805300
01-02–92
1871-1U-06B(01-02).fm 93 ページ 2006年3月15日 水曜日 午前10時32分
7
A 2Q
01-02
B 1BC
REAR HO2S
PCM
WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(HO2S related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING AND STORED Yes Go to the appropriate DTC troubleshooting procedures.
DTC (See01-02-13 DTC TABLE[L3 WITH TC].)
No Go to the next step.
Note
• If the fuel monitor, DTC P0132 is retrieved,
ignore it until P0140 is fixed.
01-02–93
1871-1U-06B(01-02).fm 94 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–94
1871-1U-06B(01-02).fm 95 ページ 2006年3月15日 水曜日 午前10時32分
3 6
C 2I
5 3 4 6
B 2R
3 6
A 2P
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related service repair information • If the vehicle is not repaired, go to the next step.
availability. No Go to the next step.
• Is any related repair information available?
01-02–95
1871-1U-06B(01-02).fm 96 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0193[L3 WITH TC]
id010239805500
01-02–96
1871-1U-06B(01-02).fm 97 ページ 2006年3月15日 水曜日 午前10時32分
3 6
C 2I
01-02
5 3 4 6
B 2R
3 7 6
A 2P
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related service repair information • If the vehicle is not repaired, go to the next step.
availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT FUEL PRESSURE SENSOR Yes Repair or replace the terminal, then go to Step 8.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel pressure sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
4 INSPECT FUEL PRESSURE SENSOR SIGNAL Yes Repair or replace the wiring harness for a possible short to
CIRCUIT FOR SHORT TO POWER SUPPLY power supply, then go to the Step 8.
• Turn the ignition switch to the ON position No Go to the next step.
(Engine off).
• Measure the voltage between the fuel pressure
sensor terminal B (wiring harness-side) and
body ground.
• Is the voltage B+?
5 INSPECT FUEL PRESSURE SENSOR Yes Replace the fuel pressure sensor, then go to Step 8.
• Inspect the fuel pressure sensor. (See01-40-35 FUEL PRESSURE SENSOR REMOVAL/
(See01-40-35 FUEL PRESSURE SENSOR INSTALLATION[L3 WITH TC].)
INSPECTION[L3 WITH TC].) No Go to the next step.
• Is there any malfunction?
01-02–97
1871-1U-06B(01-02).fm 98 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0201[L3 WITH TC]
WM: DTC P02XX
id010239805600
01-02–98
1871-1U-06B(01-02).fm 99 ページ 2006年3月15日 水曜日 午前10時32分
PCM
3 4 9 8
B 2BG 01-02
6 7
3 4 5 9 8
A 2BB
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT FUEL INJECTOR NO.1 CONNECTOR Yes Repair or replace the terminal, then go to Step 10.
FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fuel injector No.1 connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
4 INSPECT FUEL INJECTOR NO.1 CIRCUIT FOR Yes Repair or replace the wiring harness for a possible short to
SHORT TO GROUND ground, then go to Step 10.
• Turn the ignition switch off. No Go to the next step.
• Inspect for continuity between the following
terminals:
— Fuel injector No.1 terminal B (wiring
harness-side) and body ground
— Fuel injector No.1 terminal A (wiring
harness-side) and body ground
• Is there continuity?
01-02–99
1871-1U-06B(01-02).fm 100 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–100
1871-1U-06B(01-02).fm 101 ページ 2006年3月15日 水曜日 午前10時32分
3 4 9 8
B 2BH
6 7
3 4 5 9 8
A 2BC
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–101
1871-1U-06B(01-02).fm 102 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–102
1871-1U-06B(01-02).fm 103 ページ 2006年3月15日 水曜日 午前10時32分
3 4 9 8
B 2BH
6 7
3 4 5 9 8
A 2BD
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–103
1871-1U-06B(01-02).fm 104 ページ 2006年3月15日 水曜日 午前10時32分
01-02–104
1871-1U-06B(01-02).fm 105 ページ 2006年3月15日 水曜日 午前10時32分
3 4 9 8
B 2BG
6 7
3 4 5 9 8
A 2AZ
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–105
1871-1U-06B(01-02).fm 106 ページ 2006年3月15日 水曜日 午前10時32分
01-02–106
1871-1U-06B(01-02).fm 107 ページ 2006年3月15日 水曜日 午前10時32分
TP SENSOR NO.2
(THROTTLE BODY) PCM
4
3 5
B 2AO
3 6
C 2AL
7
3
D 2AP
D C B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on repair order, then go to
• Has the FREEZE FRAME DATA been the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–107
1871-1U-06B(01-02).fm 108 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–108
1871-1U-06B(01-02).fm 109 ページ 2006年3月15日 水曜日 午前10時32分
TP SENSOR NO.2
(THROTTLE BODY) PCM
5
3 7
B 2AO
3 5 7
C 2AL
3 6 7
D 2AP
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT THROTTLE BODY CONNECTOR FOR Yes Repair or replace the suspected terminal, then go to Step
POOR CONNECTION 8.
• Disconnect the throttle body connector. No Go to the next step.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
01-02–109
1871-1U-06B(01-02).fm 110 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–110
1871-1U-06B(01-02).fm 111 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT WASTEGATE CONTROL SOLENOID Yes Replace the wastegate control solenoid valve, then go to
VALVE Step 5.
• Inspect the wastegate control solenoid valve. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/
(See01-13-14 WASTEGATE CONTROL INSTALLATION[L3 WITH TC].)
SOLENOID VALVE INSPECTION[L3 WITH No Go to the next step.
TC].)
• Is there any malfunction?
4 INSPECT VACUUM HOSE Yes Repair or replace the suspected part, then go to the next
• Inspect the vacuum hose condition for the step.
following: No Go to the next step.
— Looseness
— Damage
— Improper installation
• Is there any malfunction?
5 VERIFY TROUBLESHOOTING OF DTC P0234 Yes Replace the PCM, then go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all the disconnected TC].)
connectors. No Go to the next step.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC troubleshooting.
• Perform the “AFTER REPAIR PROCEDURE”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–111
1871-1U-06B(01-02).fm 112 ページ 2006年3月15日 水曜日 午前10時32分
7
4 7 6
A B 2AA
3 3
5
PCM
WASTEGATE CONTROL SOLENOID VALVE WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B
B A
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D
01-02–112
1871-1U-06B(01-02).fm 113 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–113
1871-1U-06B(01-02).fm 114 ページ 2006年3月15日 水曜日 午前10時32分
6 5
A B 2AA
3 3
4
PCM
WASTEGATE CONTROL SOLENOID VALVE WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A
B A 2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT WASTEGATE CONTROL SOLENOID Yes Repair or replace the terminal, then go to Step 7.
VALVE CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the wastegate control solenoid
valve connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
01-02–114
1871-1U-06B(01-02).fm 115 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0300[L3 WITH TC]
WM: DTC P03XX
id010239806500
01-02–115
1871-1U-06B(01-02).fm 116 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(Misfire related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC troubleshooting.
STORED DTC (See01-02-13 DTC TABLE[L3 WITH TC].)
• Turn the ignition switch off then to the ON No Go to the next step.
position (Engine off).
• Verify related pending code or stored DTCs.
• Are other DTCs present?
4 VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect the suspected circuit and/or part according to the
(KEY TO ON/IDLE) inspection results.
• Access APP1, APP2, ECT, IAT, MAF, RPM, TP, (See01-40-6 PCM INSPECTION[L3 WITH TC].)
and VSS PIDs using the M-MDS. Then go to Step 26.
(See01-40-6 PCM INSPECTION[L3 WITH No Go to the next step.
TC].)
• Is there any signal that is far out of specification
when the ignition switch is turned to the ON
position and the engine idles?
5 VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect the suspected circuit and/or part according to the
UNDER TROUBLE CONDITION inspection results.
• Inspect the same PIDs as in Step 4 while (See01-40-6 PCM INSPECTION[L3 WITH TC].)
simulating FREEZE FRAME DATA condition. Then go to Step 26.
• Is there any signal which causes drastic No Go to the next step.
changes?
6 INSPECT CMP SENSOR Yes Go to the next step.
• Inspect the CMP sensor. No Inspect the installation condition for damage to the timing
(See01-40-45 CAMSHAFT POSITION (CMP) chain and gears, repair the malfunctioning part.
SENSOR INSPECTION[L3 WITH TC].) • If it is normal, replace the CMP sensor.
• Is the CMP sensor normal? Then go to Step 26.
01-02–116
1871-1U-06B(01-02).fm 117 ページ 2006年3月15日 水曜日 午前10時32分
01-02–117
1871-1U-06B(01-02).fm 118 ページ 2006年3月15日 水曜日 午前10時32分
01-02–118
1871-1U-06B(01-02).fm 119 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0301, P0302, P0303, P0304[L3 WITH TC]
id010239806600
01-02–119
1871-1U-06B(01-02).fm 120 ページ 2006年3月15日 水曜日 午前10時32分
01-02–120
1871-1U-06B(01-02).fm 121 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–121
1871-1U-06B(01-02).fm 122 ページ 2006年3月15日 水曜日 午前10時32分
4 7
3 5 6 8
A 2U
7
3 5 6 8
B 2V
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT KNOCK SENSOR CONNECTOR Yes Repair the terminal, then go to Step 9.
TERMINAL FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the knock sensor connector.
• Check for poor connection at terminals A and B
(such as damaged, pulled-out pins, corrosion).
• Is there any malfunction?
01-02–122
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End Of Sie
01-02–123
1871-1U-06B(01-02).fm 124 ページ 2006年3月15日 水曜日 午前10時32分
4
3 5 6
A 2U
3 5 6
B 2V
01-02–124
1871-1U-06B(01-02).fm 125 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–125
1871-1U-06B(01-02).fm 126 ページ 2006年3月15日 水曜日 午前10時32分
4
3 6
C
7 9
10
4 8
5 6
B 2W
7 9
4 8
5 9
A 2P
01-02–126
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01-02–127
1871-1U-06B(01-02).fm 128 ページ 2006年3月15日 水曜日 午前10時32分
Note
• The MAF PID should indicate 2.0 g/s
{0.26 lb/min.} or above during this test
End Of Sie
DTC P0340[L3 WITH TC]
id010239807000
01-02–128
1871-1U-06B(01-02).fm 129 ページ 2006年3月15日 水曜日 午前10時32分
4
3 6
A
7 9 01-02
10
4 8
3 5 6
C 2S
7 9
4 8
5 9
B 2P
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY CMP SENSOR VOLTAGE Yes Go to the next step.
• Disconnect the CMP sensor connector. No Go to step 10.
• Connect a voltmeter between CMP sensor
connector terminals A and C (sensor-side).
• Inspect the voltage in AC range while cranking
the engine.
• Is there any voltage?
4 INSPECT CMP SENSOR CONNECTOR FOR Yes Go to the next step.
POOR CONNECTION No Reconnect the connector, then go to Step 15.
• Verify that the CMP sensor connector is
connected securely.
• Is the connector normal?
01-02–129
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01-02–130
1871-1U-06B(01-02).fm 131 ページ 2006年3月15日 水曜日 午前10時32分
Note
• The MAF PID should indicate 1.95 g/s
{0.25 lb/min.} or above during this test
End Of Sie
DTC P0401[L3 WITH TC]
WM: DTC P04XX
id010239815300
01-02–131
1871-1U-06B(01-02).fm 132 ページ 2006年3月15日 水曜日 午前10時32分
01-02–132
1871-1U-06B(01-02).fm 133 ページ 2006年3月15日 水曜日 午前10時32分
EGR VALVE
WIRING HARNESS SIDE CONNECTOR PCM
WIRING HARNESS SIDE CONNECTOR
F D B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D
01-02–133
1871-1U-06B(01-02).fm 134 ページ 2006年3月15日 水曜日 午前10時32分
01-02–134
1871-1U-06B(01-02).fm 135 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0421[L3 WITH TC]
id010239807300
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(Catalyst related) been recorded?
01-02–135
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End Of Sie
01-02–136
1871-1U-06B(01-02).fm 137 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(Evaporative emission system related) been
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC inspection.
STORED DTCS No Go to the next step.
• Turn the ignition switch off then to the ON
position (Engine off).
• Verify related pending code or stored DTCs.
• Is DTC P0443 present?
4 DETERMINE IF LEAK CONCERN OR Yes Go to Step 6.
BLOCKAGE CONCERN No Go to the next step.
• Perform the evaporative system leak
inspection.
(See01-03-78 ENGINE CONTROL SYSTEM
OPERATION INSPECTION[L3 WITH TC].)
• Does the system inspection fail?
5 INSPECT IF PURGE SOLENOID VALVE STUCK Yes Inspect the following parts for clogging.
CLOSED • Vacuum hoses between the intake manifold to the
• Inspect if the purge solenoid valve is stuck charcoal canister
closed. • Catch tank
(See01-16-9 PURGE SOLENOID VALVE • Charcoal canister
INSPECTION[L3 WITH TC].) Repair or replace the part, then go to Step 11.
• Is the purge solenoid valve normal? No Replace the purge solenoid valve, then go to Step 11.
01-02–137
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End Of Sie
01-02–138
1871-1U-06B(01-02).fm 139 ページ 2006年3月15日 水曜日 午前10時32分
DTC P0442 Evaporative emission control system leak detected (small leak)
• PCM measures the pump load current (EVAP line pressure) when the specified period has passed after the
EVAP system is sealed when the monitoring conditions are met. If the load does not reach the reference
current value within the specified period, the PCM determines that the EVAP system has a small leak.
MONITORING CONDITION
— The ignition switch is turned off. 01-02
— IAT: 5— 35 °C {40— 95 °F}
— Battery voltage: 11— 20 V
— Atmospheric pressure: 72.2 kPa {542 mmHg, 21.3 inHg} or above
DETECTION — Fuel tank level: 15— 85%
CONDITION Diagnostic support note
• This is an intermittent monitor (Evaporative emission system).
• MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• DIAGNOSTIC MONITORING TEST RESULT is available.
• Purge solenoid valve malfunction
• EVAP system leak detection pump malfunction
• Charcoal canister malfunction
POSSIBLE • Fuel filler cap malfunction
CAUSE • Fuel tank malfunction
• Fuel pump unit poor seal
• EVAP hose damaged or loose
• EVAP pipe damaged
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(Evaporative emission system related) been
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC inspection.
STORED DTCS No Go to the next step.
• Turn the ignition switch off then to the ON
position (Engine off).
• Verify related PENDING CODE or stored
DTCs.
• Are other DTCs present?
4 CLASSIFY INTERMITTENT CONCERN OR Yes Go to the next step.
CONTINUOUS CONCERN No Intermittent concern exists. Inspect the purge solenoid
• Perform evaporative system leak inspection. valve and the EVAP system leak detection pump circuit for
(See01-03-78 ENGINE CONTROL SYSTEM an intermittent concern.
OPERATION INSPECTION[L3 WITH TC].) (See01-03-76 INTERMITTENT CONCERN
• Does the test result fail? TROUBLESHOOTING[L3 WITH TC].)
5 LOCATE LEAK POINT Yes Repair the leakage or replace the part, then go to Step 10.
• Inspect for leakage for the following using the No Go to the next step.
Evaporative Emissions Tester.
— Charcoal canister
— Catch tank
— Fuel filler cap
— EVAP hoses and pipes
— Fuel tank
• Is leakage found?
01-02–139
1871-1U-06B(01-02).fm 140 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0443[L3 WITH TC]
id010239807600
DTC P0443 EVAP control system purge control valve circuit malfunction
• PCM monitors the input voltages from the purge solenoid valve. If the voltage remains low or high, the PCM
determines that the purge solenoid valve circuit has a malfunction.
Diagnostic support note
• This is an continuous monitor (CCM).
DETECTION • MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
CONDITION one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• Purge solenoid valve malfunction
• Connector or terminal malfunction
• Short to ground in the wiring harness between purge solenoid valve terminal B and PCM terminal 2AB
POSSIBLE
• Open circuit in the wiring harness between the main relay and purge solenoid valve terminal A
CAUSE
• Open circuit in the wiring harness between purge solenoid valve terminal B and PCM terminal 2AB
• Short to the power supply between purge solenoid valve terminal B and PCM terminal 2AB
• PCM malfunction
01-02–140
1871-1U-06B(01-02).fm 141 ページ 2006年3月15日 水曜日 午前10時32分
01-02
6
B A
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 CLASSIFY OPEN CIRCUIT OR SHORT TO Yes Go to Step 5.
GROUND MALFUNCTION No Go to the next step.
• Disconnect the purge solenoid valve tube that
is connected to the intake manifold.
• Connect the vacuum pump to the purge
solenoid valve.
• Pump the vacuum pump several times and
stop.
• Wait a few seconds.
• Is the vacuum maintained?
4 INSPECT PASSAGE CONTROL OF PURGE Yes Repair or replace the wiring harness for a short to ground,
SOLENOID VALVE then go to Step 10.
• Turn the ignition switch off. No Replace the purge solenoid valve, then go to Step 10.
• Disconnect the purge solenoid valve connector.
• Pump the vacuum pump several times and wait
a few seconds.
• Is the vacuum maintained?
5 INSPECT PURGE SOLENOID VALVE Yes Repair or replace the terminal, then go to Step 10.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Inspect for poor connection (damaged/pulled-
out pins, corrosion, etc.).
• Is there any malfunction?
6 INSPECT PURGE SOLENOID VALVE Yes Go to the next step.
• Perform the purge solenoid valve inspection. No Replace the purge solenoid valve, then go to Step 10.
(See01-16-9 PURGE SOLENOID VALVE
INSPECTION[L3 WITH TC].)
• Is the purge solenoid valve normal?
01-02–141
1871-1U-06B(01-02).fm 142 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0446[L3 WITH TC]
id010239807700
DTC P0446 Change over valve (COV) (EVAP system leak detection pump) stuck close
• The PCM monitors the pump load current (EVAP line pressure), while the EVAP leak monitor is operating.
When the decrease in the pump load current is less than the specification after the reference current value
has been obtained, the PCM determines that the change over-valve (COV) in the EVAP system leak
detection pump has a malfunction.
Diagnostic support note
DETECTION • This is an intermittent monitor (CCM).
CONDITION • MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• COV (in EVAP system leak detection pump.) malfunction
POSSIBLE
• Short to the power circuit between the EVAP system leak detection pump terminal C and PCM terminal 1V
CAUSE
• PCM malfunction
01-02–142
1871-1U-06B(01-02).fm 143 ページ 2006年3月15日 水曜日 午前10時32分
01-02
M D 1AS
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(EVAP system related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnostic according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, then go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 CHECK COV CONTROL (EVAP SYSTEM LEAK Yes Repair or replace the wiring harness, then go to Step 5.
DETECTION PUMP CIRCUIT FOR SHORT TO No Go to the next step.
POWER)
• Turn ignition switch to the ON position (engine
OFF).
• Disconnect the EVAP system leak detection
pump connector.
• Measure the voltage between EVAP system
leak detection pump connector terminal C
(wiring harness-side) and body ground.
• Is the voltage B+?
4 INSPECT COV (EVAP SYSTEM LEAK Yes Go to the next step.
DETECTION PUMP) No Replace the EVAP system leak detection pump, then go to
• Inspect the EVAP system leak detection pump. the next step.
(See01-16-7 EVAPORATIVE EMISSION
(EVAP) SYSTEM LEAK DETECTION PUMP
INSPECTION[L3 WITH TC].)
• Is the COV (EVAP system leak detection
pump) normal?
01-02–143
1871-1U-06B(01-02).fm 144 ページ 2006年3月15日 水曜日 午前10時32分
Note
• If the EVAP system test function is not
available, preform the following
procedure:
— Perform “EVAP System Repair
Verification Drive Mode”.
(See01-02-10 OBD-II DRIVE
MODE[L3 WITH TC])
— Is the PENDING CODE for this DTC
present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
DTC P0455[L3 WITH TC]
id010239815500
DTC P0455 Evaporative emission control system leak detected (gross leak)
• PCM measures the pump load current (EVAP line pressure) when a specified period has passed after the
EVAP system is sealed when monitoring conditions are met. If the load does not reach the reference
current value within the specified period, the PCM determines that the EVAP system has a gross leak.
MONITORING CONDITION
— IG switch OFF
— IAT: 5— 35 °C {40— 95 °F}
— Battery voltage: 11— 20 V
— Atmospheric pressure: 72.2 kPa {542 mmHg, 21.3 inHg} or above
DETECTION — Fuel tank level: 15— 85%
CONDITION Diagnostic support note
• This is an intermittent monitor (Evaporative system monitor).
• MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• DIAGNOSTIC MONITORING TEST RESULT is available.
• Purge solenoid valve malfunction
• EVAP system leak detection pump malfunction
• Loose, missing or detective fuel filler cap
POSSIBLE • Charcoal canister malfunction
CAUSE • Fuel tank malfunction
• Fuel tank misinstallation
• EVAP hose damaged or loose
• Poor connection or damaged vacuum hose
01-02–144
1871-1U-06B(01-02).fm 145 ページ 2006年3月15日 水曜日 午前10時32分
Note
• When a fuel-filler cap other than an OEM
cap is attached, it is considered a
malfunction.
6 INSPECT IF PURGE SOLENOID VALVE IS Yes Go to the next step.
STUCK No Replace the purge solenoid valve, then go to Step 17.
• Inspect the purge solenoid valve.
• Is the purge solenoid valve normal?
7 INSPECT COV (EVAP SYTEM LEAK Yes Go to the next step.
DETECTION PUMP) No Replace the EVAP system leak detection pump, then go to
• Inspect the EVAP system leak detection pump. Step 17.
• Is the COV (EVAP leak detection pump)
normal?
8 DETERMINE IF EVAP CONTROL SYSTEM FOR Yes Repair or replace malfunctioning area, then go to Step 17.
LEAKAGE OR BLOCKAGE No Go to the next step.
Note
• If the evaporative emission tester is not
available, then go to the next step.
01-02–145
1871-1U-06B(01-02).fm 146 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–146
1871-1U-06B(01-02).fm 147 ページ 2006年3月15日 水曜日 午前10時32分
DTC P0456 Evaporative emission control system leak detected (very small leak)
• PCM measures the pump load current (EVAP line pressure) when a specified period has passed after the
EVAP system is sealed when monitoring conditions are met. If the load does not reach the reference load
value or the rate of the load increase is lower than the specification within a specified period, the PCM
determines that the EVAP system has a very small leak.
MONITORING CONDITION 01-02
— IG switch OFF
— IAT: 5— 35 °C {40— 95 °F}
— Battery voltage: 11— 20 V
— Atmospheric pressure: 72.2 kPa {542 mmHg, 21.3 inHg} or above
DETECTION
— Fuel tank level: 15— 85%
CONDITION
Diagnostic support note
• This is an intermittent monitor (Evaporative system monitor).
• MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• DIAGNOSTIC MONITORING TEST RESULT is available.
• Purge solenoid valve malfunction
• EVAP system leak detection pump malfunction
• Charcoal canister malfunction
POSSIBLE • Fuel cap malfunction
CAUSE • Fuel tank malfunction
• Fuel pump unit poor seal
• EVAP hose damaged or loose
• EVAP pipe damaged
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(Evaporative emission system related) been
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the appropriate DTC inspection.
STORED DTCS No Go to the next step.
• Turn the ignition switch off then ON position
(Engine off).
• Verify related PENDING CODE or stored
DTCs.
• Are other DTC present?
4 CLASSIFY INTERMITTENT CONCERN OR Yes Go to the next step.
CONTINUOUS CONCERN No Intermittent concern exists. Inspect the purge solenoid
• Perform the evaporative system leak valve and the EVAP system leak detection pump circuit for
inspection. an intermittent concern.
(See01-03-78 ENGINE CONTROL SYSTEM (See01-03-76 INTERMITTENT CONCERN
OPERATION INSPECTION[L3 WITH TC].) TROUBLESHOOTING[L3 WITH TC].)
• Does the system test result fail?
01-02–147
1871-1U-06B(01-02).fm 148 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–148
1871-1U-06B(01-02).fm 149 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT FUEL GAUGE SENDER UNIT Yes Replace the PCM, then go to the next step.
• Turn the ignition switch off. No Repair or replace the fuel gauge sender unit, then go to the
• Inspect the fuel gauge sender unit. next step.
(See09-22-14 FUEL GAUGE SENDER UNIT
INSPECTION.)
• Is the fuel gauge sender unit normal?
4 INSPECT INSTRUMENT CLUSTER Yes Repair or replace the suspected malfunction, then go to the
• Perform the “INSTRUMENT CLUSTER INPUT/ next step.
OUTPUT CHECK MODE” procedure. No Go to the next step.
(See 09-22-5 INSTRUMENT CLUSTER
INPUT/OUTPUT CHECK MODE.)
• Is there any malfunction?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–149
1871-1U-06B(01-02).fm 150 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT FUEL GAUGE SENDER UNIT Yes Replace the PCM, then go to the next step.
• Turn the ignition switch off. No Repair or replace the fuel gauge sender unit, then go to the
• Inspect the fuel gauge sender unit. next step.
(See09-22-14 FUEL GAUGE SENDER UNIT
INSPECTION.)
• Is the fuel gauge sender unit normal?
4 INSPECT INSTRUMENT CLUSTER Yes Repair or replace the suspected malfunction, then go to the
• Perform the “INSTRUMENT CLUSTER INPUT/ next step.
OUTPUT CHECK MODE” procedure. No Go to the next step.
(See 09-22-5 INSTRUMENT CLUSTER
INPUT/OUTPUT CHECK MODE.)
• Is there any malfunction?
5 VERIFY TROUBLESHOOTING OF DTC P0462 Yes Replace PCM, then go to the next step.
COMPLETED No Go to the next step.
• Make sure to reconnect all disconnected
connectors.
• Turn ignition switch to the ON position (Engine
off).
• Clear the DTC from the memory using the M-
MDS.
• Start the engine.
• Is the PENDING CODE for this DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 01-02-13 DTC TABLE[L3 WITH TC].)
(See 01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–150
1871-1U-06B(01-02).fm 151 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT FUEL GAUGE SENDER UNIT Yes Replace the PCM, then go to the next step.
• Turn the ignition switch off. No Repair or replace the fuel gauge sender unit, then go to the
• Inspect the fuel gauge sender unit. next step.
(See09-22-14 FUEL GAUGE SENDER UNIT
INSPECTION.)
• Is the fuel gauge sender unit normal?
4 INSPECT INSTRUMENT CLUSTER Yes Repair or replace the suspected malfunction, then go to the
• Perform “INSTRUMENT CLUSTER INPUT/ next step.
OUTPUT CHECK MODE” procedure. No Go to the next step.
(See 09-22-5 INSTRUMENT CLUSTER
INPUT/OUTPUT CHECK MODE.)
• Is there any malfunction?
5 VERIFY TROUBLESHOOTING OF DTC P0463 Yes Replace the PCM, then go to the next step.
COMPLETED No Go to the next step.
• Make sure to reconnect all disconnected
connectors.
• Turn ignition switch to the ON position (Engine
off).
• Clear the DTC from the memory using the M-
MDS.
• Start the engine.
• Is the PENDING CODE for this DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 01-02-13 DTC TABLE[L3 WITH TC].)
(See 01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–151
1871-1U-06B(01-02).fm 152 ページ 2006年3月15日 水曜日 午前10時32分
1A
3 4 5 6
8 1B 1AE
7
1C
01-02–152
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End Of Sie
01-02–153
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2A
3 4 5 6
8 2B 1R
7
2C
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT FAN CONTROL MODULE No.2 Yes Repair or replace the terminal, then go to Step 9.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the fan control module No.2
connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
01-02–154
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
ON-BOARD DIAGNOSTIC [L3 WITH TC]
STEP INSPECTION ACTION
4 INSPECT FAN CONTROL MODULE No.2 Yes Repair or replace the wiring harness for an open circuit,
SIGNAL CIRCUIT FOR SHORT TO POWER then go to Step 9.
SUPPLY No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Measure the voltage between fan control
module No.2 terminal 2B (wiring harness-side) 01-02
and body ground.
• Is the voltage B+?
5 INSPECT FAN CONTROL MODULE No.2 Yes Repair or replace the wiring harness for an open circuit,
SIGNAL CIRCUIT FOR SHORT TO GROUND then go to Step 9.
• Turn the ignition switch off. No Go to the next step.
• Inspect for continuity between fan control
module No.2 terminal 2B (wiring harness-side)
and body ground.
• Is there continuity?
6 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to Step 9.
CONNECTION No Go to the next step.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
7 INSPECT FAN CONTROL MODULE No.2 Yes Go to the next step.
SIGNAL CIRCUIT FOR OPEN CIRCUIT No Repair or replace the wiring harness for an open circuit,
• Inspect for continuity between fan control then go to Step 9.
module No.2 terminal 2B (wiring harness-side)
and PCM terminal 1R.
• Is there continuity?
8 INSPECT FAN CONTROL MODULE No.2 Yes Go to the next step.
• Perform the fan control module No.2 No Replace the fan control module No.2, then go to the next
inspection. step.
(See01-03-78 ENGINE CONTROL SYSTEM
OPERATION INSPECTION[L3 WITH TC].)
• Is the fan control module No.2 normal?
9 VERIFY TROUBLESHOOTING OF DTC P0481 Yes Replace the PCM, then go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Clear the DTC from the PCM memory using TC].)
the M-MDS. No Go to the next step.
• Start the engine.
• Turn A/C switch to ON.
• Is the same DTC present?
10 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
DTC P050A[L3 WITH TC]
WM: DTC P05XX
id010239800000
Note
• If atmospheric pressure is less than 72.3 kPa {542 mmHg, 21.3 inHg} or intake air temperature is
below -10 °C {14 °F}, the PCM cancels diagnosis of P0506.
DETECTION
CONDITION
Diagnostic support note
• This is a continuous monitor (CCM).
• The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or
in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTC is stored in the PCM memory.
01-02–155
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
ON-BOARD DIAGNOSTIC [L3 WITH TC]
DTC P050A Cold start idle air control system performance
• The air into the fuel line by exchange or re-installation
• Electronic throttle control system malfunction
POSSIBLE
• Throttle valve stuck or blockage
CAUSE • Air suction in intake air system
• PCM malfunction
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and diagnostic
HAVE BEEN RECORDED monitoring test results on the repair order, then go to the
• Have FREEZE FRAME DATA and next step.
DIAGNOSTIC MONITORING TEST RESULTS
(CCM related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA No Go to troubleshooting procedures for DTC on FREEZE
• Is P050A on FREEZE FRAME DATA? FRAME DATA.
(See01-02-13 DTC TABLE[L3 WITH TC].)
4 INSPECT FUEL SYSTEM Yes Perform the air bleeding of fuel system.
• Were any exchange or re-installation of fuel • Start the engine and warm it up until engine speed is
system performed just before the P050A stable then go to the next step.
stored? No Go to Step 6.
5 CONFIRM THE PENDING CODE Yes Go to the next step.
• Clear the DTC from the PCM memory using No Go to Step 9.
the M-MDS.
• Cool down the engine still ECT below 30 °C {86
°F}.
• Perform the cold start.
• Is the PENDING CODE for this DTC present?
6 CHECK AIR SUCTION IN INTAKE AIR SYSTEM Yes Repair or replace malfunctioning part, then go to Step 9.
• Start the engine. No Go to the next step.
• Check air suction between MAF sensor and
intake manifold.
• Is there any air suction in the intake air
system?
7 VERIFY ELECTRONIC THROTTLE CONTROL Yes Go to the next step.
SYSTEM OPERATION No Repair or replace malfunctioning part according to
• Perform the Electronic Throttle Control System inspection result.
Operation Inspection. Then go to Step 9.
(See01-03-78 ENGINE CONTROL SYSTEM
OPERATION INSPECTION[L3 WITH TC],
Electronic Throttle Control System Inspection.)
• Does the electronic throttle control system
operate properly?
8 VERIFY THROTTLE VALVE Yes Go to the next step.
• Turn the ignition switch off. No Clean the throttle valve and retest.
• Remove the throttle valve with connector If the problem does not resolve, replace the throttle body.
connected. Then go to the next step.
• Access ETC_DSD PID using the M-MDS.
• Turn the ignition switch to ON position (Engine
off).
• Move the throttle valve using the ETC_DSD
PID simulation function.
• Dose the throttle valve move smoothly?
9 VERIFY TROUBLESHOOTING OF DTC P050A Yes Replace the PCM, then go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all disconnected TC].)
connectors. No Go to the next step.
• Clear DTC from the PCM memory using the M-
MDS.
• Perform the KOER self-test using the M-MDS.
(See01-02-13 DTC TABLE[L3 WITH TC].)
• Is the PENDING CODE for this DTC present?
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME PID DATA on the repair order,
• Has the FREEZE FRAME PID DATA been then go to the next step.
recorded?
2 VERIFY RELATED SERVICE INFORMATION Yes Perform the repair or diagnosis according to available
AVAILABILITY Service Information.
• Check for related Service Information • If the vehicle is not repaired, go to the next step.
availability. No Go to the next step.
• Is any related Service Information available?
3 VERIFY STORED DTC IN DSC HU/CM Yes Go to the appropriate DTC inspection.
• Turn the ignition switch to the ON position (See04-02-3 ON-BOARD DIAGNOSIS.)
(Engine off). No Go to the next step.
• Verify stored DTCs in the DSC HU/CM.
(See04-02-3 ON-BOARD DIAGNOSIS.)
• Are DTCs stored?
01-02–158
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End Of Sie
DTC P0505[L3 WITH TC]
id010239808500
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
2 VERIFY RELATED PENDING OR STORED DTCs Yes Perform the applicable DTC troubleshooting.
• Turn the ignition switch off then to the ON (See01-02-13 DTC TABLE[L3 WITH TC].)
position. (Engine off) No Go to the next step.
• Verify pending code or stored DTCs using the
M-MDS.
• Are DTCs P0506, P0507, P0638, P2100,
P2101, P2102, P2103, P2108, or P2119
present?
3 VERIFY ELECTRONIC THROTTLE CONTROL Yes Go to the next step.
SYSTEM OPERATION No Repair or replace the malfunctioning part according to the
• Perform the TP sweep inspection. inspection result.
(See01-03-78 ENGINE CONTROL SYSTEM Then go to Step 9.
OPERATION INSPECTION[L3 WITH TC].)
• Does the electronic throttle control system
work properly?
01-02–159
1871-1U-06B(01-02).fm 160 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0506[L3 WITH TC]
id010239808600
Note
• If the atmospheric pressure is less than 72.3 kPa {542 mmHg, 21.3 inHg} or the intake air temperature
is below –10 °C {14 °F}, the PCM cancels the diagnosis of P0506.
DETECTION
CONDITION Diagnostic support note
• This is a continuous monitor (CCM).
• MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in PCM memory.
• Electronic throttle control system malfunction
• Air cleaner element clogged
• Air intake passage clogged
POSSIBLE • A/C relay control circuit malfunction
CAUSE • Generator malfunction
• Purge solenoid valve malfunction
• Low engine compression (Over capacity of blow-by gas)
• PCM malfunction
01-02–160
1871-1U-06B(01-02).fm 161 ページ 2006年3月15日 水曜日 午前10時32分
01-02–161
1871-1U-06B(01-02).fm 162 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0507[L3 WITH TC]
id010239808700
Note
• If the atmospheric pressure is less than 72.3 kPa {542 mmHg, 21.3 inHg} or the intake air temperature
is below –10 °C {14 °F}, the PCM cancels diagnosis of P0507.
DETECTION
CONDITION
Diagnostic support note
• This is a continuous monitor (CCM).
• MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in PCM memory.
• Electronic throttle control system malfunction
POSSIBLE
• Vacuum hose misconnection
CAUSE
• PCM malfunction
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED SERVICE INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, then go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING OR STORED Yes Repair applicable DTCs.
DTCS (See01-02-13 DTC TABLE[L3 WITH TC].)
• Turn ignition switch to off, then ON position No Go to the next step.
(Engine off).
• Verify pending code or stored DTCs using the
M-MDS.
• Are other DTCs present?
4 INSPECT VACUUM HOSE CONNECTION Yes Go to the next step.
• Are the vacuum hoses connecting accurately? No Reconnect the vacuum hoses correctly, then go to step 6.
(See01-13-4 VACUUM HOSE ROUTING
DIAGRAM[L3 WITH TC].)
01-02–162
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End Of Sie
01-02–163
1871-1U-06B(01-02).fm 164 ページ 2006年3月15日 水曜日 午前10時32分
5 7 6
2T
3
A
PSP SWITCH 4
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair formation availability. No Go to the next step.
• Is any related repair information available?
01-02–164
1871-1U-06B(01-02).fm 165 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–165
1871-1U-06B(01-02).fm 166 ページ 2006年3月15日 水曜日 午前10時32分
5 3 4
2 1AQ
PCM
CRUISE CONTROL SWITCH WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
01-02–166
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End Of Sie
01-02–167
1871-1U-06B(01-02).fm 168 ページ 2006年3月15日 水曜日 午前10時32分
4 4
C A
6
1AF
7 8
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair, then go to the
• Has the FREEZE FRAME DATA been next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–168
1871-1U-06B(01-02).fm 169 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
WM: DTC P06XX
01-02–169
1871-1U-06B(01-02).fm 170 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY TROUBLESHOOTING OF P0601 Yes Replace the PCM, go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all disconnected TC].)
connectors. No Go to the next step.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
DTC P0602[L3 WITH TC]
id010239809200
Note
• If the “PCM CONFIGURATION” is successful, the PCM stores DTC P0602 and illuminates the MIL
(System is normal). Clear DTC P0602 using the M-MDS after the “PCM CONFIGURATION”.
DETECTION • MIL turns off after three drive cycles with no failure (DTCs remain in PCM).
CONDITION
Diagnostic support note
• This is a continuous monitor (CCM).
• MIL illuminates if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in PCM memory.
POSSIBLE • Configuration has not been completed.
CAUSE • PCM malfunction
01-02–170
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End Of Sie
DTC P0604[L3 WITH TC]
id010239809300
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY TROUBLESHOOTING OF P0604 Yes Replace the PCM, go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all disconnected TC].)
connectors. No Go to the next step.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
01-02–171
1871-1U-06B(01-02).fm 172 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY TROUBLESHOOTING OF P0606 Yes Replace PCM, go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all disconnected TC].)
connectors. No Go to the next step.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start engine.
• Is same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
DTC P0607[L3 WITH TC]
id010239809500
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on repair order, then go to
• Has FREEZE FRAME DATA been recorded? the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–172
1871-1U-06B(01-02).fm 173 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P0610[L3 WITH TC]
id010239809600
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY TROUBLESHOOTING OF DTC P0610 Yes Replace the PCM, then go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all disconnected TC].)
connectors. No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC troubleshooting.
• Perform the “AFTER REPAIR PROCEDURE”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–173
1871-1U-06B(01-02).fm 174 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on repair order, then go to
• Has FREEZE FRAME DATA been recorded? the next step.
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT FOR OTHER DTCS Yes Perform the diagnostic procedure for the applicable DTCs.
• Have other DTCs been stored? No Go to the next step.
4 INSPECT THROTTLE ACTUATOR Yes Go to the next step.
• Inspect the throttle actuator. (See 01-13-12 No Replace the throttle body, then go to the next step.
THROTTLE ACTUATOR INSPECTION[L3
WITH TC])
• Is the throttle actuator normal?
5 VERIFY TROUBLESHOOTING OF P0638 Yes Replace the PCM, go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all disconnected TC].)
connectors. No Go to the next step.
• Clear the DTC from the PCM memory using
the M-MDS.
• Turn the ignition switch off.
• Start the engine and let it idle.
• Is the same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
DTC P0703[L3 WITH TC]
WM: DTC P07XX
id010239809900
01-02–174
1871-1U-06B(01-02).fm 175 ページ 2006年3月15日 水曜日 午前10時32分
B
12 6 8
BRAKE 1AB
SWITCH
9
D 13
4 10
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 CLASSIFY HIGH INPUT OR LOW INPUT Yes Go to the next step.
• Connect the M-MDS to the DLC-2. No Go to Step 10.
• Access the BOO PID.
• Verify the BOO PID during brake pedal
operation.
• Is the BOO PID always off?
4 INSPECT BRAKE SWITCH CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 14.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch to off.
• Disconnect the brake switch connector.
• Inspect for poor connection (such as damaged
pulled-out terminals, corrosion).
• Is there any malfunction?
01-02–175
1871-1U-06B(01-02).fm 176 ページ 2006年3月15日 水曜日 午前10時32分
01-02–176
1871-1U-06B(01-02).fm 177 ページ 2006年3月15日 水曜日 午前10時32分
id010239815600
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY STORED DTC IN INSTRUMENT Yes Go to the applicable DTC inspection.
CLUSTER No Go to the next step.
• Turn the ignition switch to the ON position
(Engine off).
• Verify stored DTCs in instrument cluster.
• Are DTCs stored?
4 VERIFY TROUBLESHOOTING OF DTC P1260 Yes Replace the PCM, then go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all the disconnected TC].)
connectors. No Go to the next step.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine or perform the KOEO self-test
with M-MDS.
• Is PENDING CODE for this DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-02-10 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
WM: DTC P20XX
01-02–177
1871-1U-06B(01-02).fm 178 ページ 2006年3月15日 水曜日 午前10時32分
DTC P2004 Variable swirl control system shutter valve stuck open
• PCM monitors the mass variable swirl shutter valve position using the variable swirl shutter valve switch. If
the PCM turns variable swirl solenoid valve on but variable swirl shutter valve position still remains open
(variable swirl shutter valve switch is on), the PCM determines that the variable swirl shutter valve is stuck
open.
Diagnostic support note
DETECTION • This is a continuous monitor (CCM).
CONDITION • MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in PCM memory.
• Variable swirl shutter valve actuator malfunction (stuck open)
• Misconnected or pulled out vacuum hose
• Variable swirl shutter valve switch malfunction
• Variable swirl solenoid valve malfunction
• Connector or terminal malfunction
• Open circuit in the wiring harness between variable swirl solenoid valve terminal B and PCM terminal 2AS
POSSIBLE
• Short to power in the wiring harness between variable swirl solenoid valve terminal B and PCM terminal
CAUSE
2AS
• Open circuit in the wiring harness between variable swirl shutter valve switch terminal A and PCM terminal
2AE
• Short to power in the wiring harness between variable swirl shutter valve switch terminal A and PCM
terminal 2AE
• PCM malfunction
MAIN RELAY PCM
VARIABLE SWIRL
SOLENOID VALVE
9 9 11 10
A B 2AS
5 12
11 10
A 2AE
9 12
7
A B
01-02–178
1871-1U-06B(01-02).fm 179 ページ 2006年3月15日 水曜日 午前10時32分
01-02–179
1871-1U-06B(01-02).fm 180 ページ 2006年3月15日 水曜日 午前10時32分
01-02–180
1871-1U-06B(01-02).fm 181 ページ 2006年3月15日 水曜日 午前10時32分
DTC P2006 Variable swirl control system shutter valve stuck closed
• PCM monitors the mass variable swirl shutter valve position using the variable swirl shutter valve switch. If
PCM turns the variable swirl solenoid valve off but the variable swirl position still remains closed (variable
swirl shutter valve switch is off), the PCM determines that the variable swirl shutter valve is stuck closed.
Diagnostic support note
DETECTION • This is a continuous monitor (CCM). 01-02
CONDITION • MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in PCM memory.
• ECT sensor malfunction
• TP sensor malfunction
• CKP sensor malfunction
• Connector or terminal malfunction
• Variable swirl solenoid valve malfunction
POSSIBLE
• Variable swirl shutter valve malfunction (stuck closed)
CAUSE
• Variable swirl shutter valve actuator malfunction (stuck closed).
• Short to ground circuit between variable swirl solenoid valve terminal B and PCM terminal 2AS
• Short to ground in the wiring harness between variable swirl shutter valve switch terminal A and PCM
terminal 2AE
• PCM malfunction
MAIN RELAY PCM
VARIABLE SWIRL
SOLENOID VALVE
7 7 9 8
A B 2AS
6
7
B
A B
01-02–181
1871-1U-06B(01-02).fm 182 ページ 2006年3月15日 水曜日 午前10時32分
01-02–182
1871-1U-06B(01-02).fm 183 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–183
1871-1U-06B(01-02).fm 184 ページ 2006年3月15日 水曜日 午前10時32分
VARIABLE SWIRL
SOLENOID VALVE
5
7 8 6
A B 2AS
3 3
4
B A
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT VARIABLE SWIRL SOLENOID VALVE Yes Repair or replace the terminal, then go to Step 9.
CONNECTOR FOR POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
01-02–184
1871-1U-06B(01-02).fm 185 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–185
1871-1U-06B(01-02).fm 186 ページ 2006年3月15日 水曜日 午前10時32分
VARIABLE SWIRL
SOLENOID VALVE
6 5
A B 2AS
3 3
4
01-02–186
1871-1U-06B(01-02).fm 187 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–187
1871-1U-06B(01-02).fm 188 ページ 2006年3月15日 水曜日 午前10時32分
OCV
5
7 8 6
B A 2AF
3 3
4
OCV PCM
WIRING HARNESS SIDE CONNECTOR HARNESS SIDE CONNECTOR
B A
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D
01-02–188
1871-1U-06B(01-02).fm 189 ページ 2006年3月15日 水曜日 午前10時32分
01-02–189
1871-1U-06B(01-02).fm 190 ページ 2006年3月15日 水曜日 午前10時32分
OCV
6 5
B A 2AF
3 3
4
OCV PCM
WIRING HARNESS SIDE CONNECTOR HARNESS SIDE CONNECTOR
B A
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT OCV CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to Step 7.
CONNECTION No Go to the next step.
• Turn the ignition switch to off.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
4 INSPECT OCV Yes Go to the next step.
• Perform the OCV inspection. No Replace the OCV, then go to Step 7.
(See01-10-29 OIL CONTROL VALVE (OCV)
INSPECTION[L3 WITH TC].)
• Is the OCV normal?
01-02–190
1871-1U-06B(01-02).fm 191 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P2096[L3 WITH TC]
id010239810800
01-02–191
1871-1U-06B(01-02).fm 192 ページ 2006年3月15日 水曜日 午前10時32分
01-02–192
1871-1U-06B(01-02).fm 193 ページ 2006年3月15日 水曜日 午前10時32分
01-02–193
1871-1U-06B(01-02).fm 194 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P2097[L3 WITH TC]
id010239810900
01-02–194
1871-1U-06B(01-02).fm 195 ページ 2006年3月15日 水曜日 午前10時32分
01-02–195
1871-1U-06B(01-02).fm 196 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
WM: DTC P21XX
01-02–196
1871-1U-06B(01-02).fm 197 ページ 2006年3月15日 水曜日 午前10時32分
4 8 9 7
F 2A
4 10 11 7
E 2B
PCM
THROTTLE BODY
WIRING HARNESS SIDE CONNECTOR
HARNESS SIDE CONNECTOR
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–197
1871-1U-06B(01-02).fm 198 ページ 2006年3月15日 水曜日 午前10時32分
01-02–198
1871-1U-06B(01-02).fm 199 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING AND STORED Yes Go to appropriate DTC troubleshooting procedure.
DTCS No Go to the next step.
• Turn ignition switch to OFF, then ON (Engine
off).
• Verify pending and stored DTCs using the M-
MDS.
• Are any DTCs present?
4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA No Go to troubleshooting procedures for DTC on FREEZE
• Is DTC P2101 on FREEZE FRAME DATA? FRAME DATA.
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to Step 22.
CONNECTION No Go to the next step.
• Turn the ignition switch to off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged,
pulled out terminals, corrosion).
• Is there any malfunction?
6 INSPECT MAIN RELAY OUTPUT VOLTAGE Yes Go to Step 13.
• Turn the ignition switch to off. No Go to the next step.
• Connect the PCM connector.
• Turn ignition switch to the ON position (Engine
off).
• Measure the voltage between PCM terminal
1BE and body ground.
• Is the voltage B+?
01-02–199
1871-1U-06B(01-02).fm 200 ページ 2006年3月15日 水曜日 午前10時32分
01-02–200
1871-1U-06B(01-02).fm 201 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–201
1871-1U-06B(01-02).fm 202 ページ 2006年3月15日 水曜日 午前10時32分
9
4 5 6 7
F 2A
4 8 7
E 2B
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–202
1871-1U-06B(01-02).fm 203 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–203
1871-1U-06B(01-02).fm 204 ページ 2006年3月15日 水曜日 午前10時32分
4
F 2A
3
E 2B
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–204
1871-1U-06B(01-02).fm 205 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P2107[L3 WITH TC]
id010239811400
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY TROUBLESHOOTING OF P2107 Yes Replace the PCM, then go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all disconnected TC].)
connectors. No Go to the next step.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
01-02–205
1871-1U-06B(01-02).fm 206 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P2108[L3 WITH TC]
id010239811500
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING CODE AND Yes Go to appropriate DTC troubleshooting procedure, then go
STORED DTCS to Step 7.
• Turn ignition switch to OFF, then ON (Engine No Go to the next step.
off).
• Verify pending and/or stored DTCs using the
M-MDS.
• Is the DTC P0122, P0123, P0222 or P0223
also present?
4 VERIFY INTERMITTENT MALFUNCTION AT TP Yes Repair or replace malfunctioning part, according to
SENSOR NO.1 CIRCUIT inspection result, the go to Step 7.
• Perform the INTERMITTENT No Go to the next step.
TROUBLESHOOTING procedure to TP sensor
No.1 related harnesses and connectors.
(See01-03-76 INTERMITTENT CONCERN
TROUBLESHOOTING[L3 WITH TC].)
• Is there any malfunction?
01-02–206
1871-1U-06B(01-02).fm 207 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P2119[L3 WITH TC]
id010239811600
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT THROTTLE ACTUATOR Yes Replace the throttle body, then go to Step 5.
• Inspect the throttle actuator. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/
(See01-13-12 THROTTLE ACTUATOR INSTALLATION[L3 WITH TC].)
INSPECTION[L3 WITH TC].) No Go to the next step.
• Is there any malfunction?
4 INSPECT TP SENSOR Yes Replace the TP sensor, then go to the next step.
• Inspect the TP sensor. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/
(See01-13-12 THROTTLE ACTUATOR INSTALLATION[L3 WITH TC].)
INSPECTION[L3 WITH TC].) No Go to the next step.
• Is there any malfunction?
01-02–207
1871-1U-06B(01-02).fm 208 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P2122[L3 WITH TC]
id010239811700
DTC P2122 Accelerator pedal position (APP) sensor No.1 circuit low input
• The PCM monitors the APS No.1 signal. If the PCM detects that the APP sensor No.1 voltage is below 0.2
V, the PCM determines that the APP sensor No.1 circuit has a malfunction.
Diagnostic support note
DETECTION
CONDITION • This is a continuous monitor (CCM).
• MIL illuminates if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• APP sensor malfunction
• Connector or terminal malfunction
POSSIBLE • Open circuit between APP sensor terminal F and PCM terminal 1Y
CAUSE • Short to ground circuit between APP sensor terminal F and PCM terminal 1Y
• Open circuit between APP sensor terminal D and PCM terminal 1Q
• Short to ground between APP sensor terminal D and PCM terminal 1Q
APP SENSOR PCM
4
3 5
D 1Q
3 6
F 1Y
7 8
E 1U
01-02–208
1871-1U-06B(01-02).fm 209 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–209
1871-1U-06B(01-02).fm 210 ページ 2006年3月15日 水曜日 午前10時32分
DTC P2123 Accelerator pedal position (APP) sensor No.1 circuit high input
• The PCM monitors the APP sensor No.1 signal. If the PCM detects that the APP sensor No.1 voltage is
above 4.5 V, the PCM determines that the APP sensor No.1 circuit has a malfunction.
Diagnostic support note
DETECTION
CONDITION • This is a continuous monitor (CCM).
• MIL illuminates if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• APP sensor malfunction
• Connector or terminal malfunction
POSSIBLE
• Open circuit between APP sensor terminal E and PCM terminal 1U
CAUSE
• Open circuit between APP sensor terminal F and PCM terminal 1Y
• Short to power supply circuit between APP sensor terminal F and PCM terminal 1Y
APP SENSOR PCM
5
3 4 9 8
D 1Q
3 4 6 9 8
F 1Y
3 4 8
E 1U
7
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT APP SENSOR CONNECTOR Yes Go to the next step.
• Turn the ignition switch to off. No Connect the connector securely, then go to Step 10.
• Verify that the APP sensor connector is
connected securely.
• Is the connector normal?
01-02–210
1871-1U-06B(01-02).fm 211 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–211
1871-1U-06B(01-02).fm 212 ページ 2006年3月15日 水曜日 午前10時32分
DTC P2127 Accelerator pedal position (APP) sensor No.2 circuit low input
• The PCM monitors the APP sensor No.2 signal. If the PCM detects that the APP sensor No.2 voltage is
below 0.2 V, the PCM determines that the APP sensor No.2 circuit has a malfunction.
Diagnostic support note
DETECTION
CONDITION • This is a continuous monitor (CCM).
• MIL illuminates if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• APP sensor malfunction
• Connector or terminal malfunction
POSSIBLE
• Open circuit between APP sensor terminal C and PCM terminal 1AC
CAUSE
• Short to ground circuit between APP sensor terminal C and PCM terminal 1AC
• Open circuit between APP sensor terminal A and PCM terminal 1AJ
APP SENSOR PCM
4
3 5
A 1AJ
3 6
C 1AC
7
B 1AV
01-02–212
1871-1U-06B(01-02).fm 213 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–213
1871-1U-06B(01-02).fm 214 ページ 2006年3月15日 水曜日 午前10時32分
DTC P2128 Accelerator pedal position (APP) sensor No.2 circuit high input
• The PCM monitors the APP sensor No.2 signal. If the PCM detects that the APP sensor No.2 voltage is
above 4.5 V, the PCM determines that the APP sensor No.2 circuit has a malfunction.
Diagnostic support note
DETECTION
CONDITION • This is a continuous monitor (CCM).
• MIL illuminates if the PCM detects the above malfunction condition during the first drive cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• APP sensor malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Open circuit between APP sensor terminal B and PCM terminal 1AV
• Short to power supply circuit between APP sensor terminal C and PCM terminal 1AC
APP SENSOR PCM
5
3 4 9 8
A 1AJ
3 4 6 9 8
C 1AC
3 4 8
B 1AV
7
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT APP SENSOR CONNECTOR Yes Go to the next step.
• Turn the ignition switch to off. No Connect the connector securely, then go to Step 10.
• Verify that the APP sensor connector is
connected securely.
• Is the connector normal?
01-02–214
1871-1U-06B(01-02).fm 215 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–215
1871-1U-06B(01-02).fm 216 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT THROTTLE BODY CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 6.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch to off.
• Disconnect the throttle body connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
4 INSPECT TP SENSOR Yes Replace the throttle body, then go to Step 6.
• Inspect the TP sensor. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/
(See01-40-32 THROTTLE POSITION (TP) INSTALLATION[L3 WITH TC].)
SENSOR INSPECTION[L3 WITH TC].) No Go to the next step.
• Is there any malfunction?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to the next step.
CONNECTION No Go to the next step.
• Turn the ignition switch to off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
6 VERIFY TROUBLESHOOTING OF DTC P2135 Yes Replace the PCM, then go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all disconnected TC].)
connectors. No Go to the next step.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–216
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Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT APP SENSOR CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 6.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch to off.
• Disconnect the APP sensor connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
4 INSPECT APP SENSOR Yes Replace the APP sensor, then go to Step 6.
• Inspect the APP sensor. (See01-13-17 ACCELERATOR PEDAL REMOVAL/
(See01-40-33 ACCELERATOR PEDAL INSTALLATION[L3 WITH TC].)
POSITION (APP) SENSOR INSPECTION[L3 No Go to the next step.
WITH TC].)
• Is there any malfunction?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair or replace the terminal, then go to the next step.
CONNECTION No Go to the next step.
• Turn the ignition switch to off.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
6 VERIFY TROUBLESHOOTING OF DTC P2138 Yes Replace the PCM, then go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all disconnected TC].)
connectors. No Go to the next step.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “AFTER REPAIR PROCEDURE”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–217
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Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(Fuel system related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING CODE OR Yes If misfire the DTC is present, go to Step 8.
STORED DTCS If other DTCs is present, go to the applicable DTC
• Turn the ignition switch to off, then to the ON inspection.
position (Engine off). (See01-02-13 DTC TABLE[L3 WITH TC].)
• Verify related pending code or stored DTCs. No If driveability concern is present, go to Step 8.
• Are other DTCs present? If not, go to the next step.
4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA No Go to troubleshooting procedures for DTC on FREEZE
• Is DTC P2177 on FREEZE FRAME DATA? FRAME DATA.
5 VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect the sensor and excessive resistance in related
(IGNITION SWITCH TO THE ON POSITION/ wiring harnesses.
IDLE) Repair if necessary.
• Access the APP1, APP2, ECT, MAF, TP and Then go to Step 20.
VSS PIDs using the M-MDS. No Go to the next step.
• Is there any signal that is far out of specification
when the ignition switch is at the ON position
and the engine runs?
01-02–218
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01-02–219
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End Of Sie
DTC P2178[L3 WITH TC]
id010239812400
01-02–220
1871-1U-06B(01-02).fm 221 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(Fuel system related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING CODE OR Yes If misfire the DTC is present, go to Step 8.
STORED DTCS If other DTCs is present, go to the applicable DTC
• Turn the ignition switch to off, then to the ON inspection.
position (Engine off). (See01-02-13 DTC TABLE[L3 WITH TC].)
• Verify related pending code or stored DTCs. No If driveability concern is present, go to Step 8.
• Are other DTCs present? If not, go to the next step.
4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA No Go to troubleshooting procedures for DTC on FREEZE
• Is DTC P2178 on FREEZE FRAME DATA? FRAME DATA.
5 VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect the sensor and excessive resistance in related
(IGNITION SWITCH TO THE ON POSITION/ wiring harnesses.
IDLE) Repair if necessary.
• Access the APP1, APP2, ECT, MAF, TP and Then go to Step 19.
VSS PIDs using the M-MDS. No Go to the next step.
• Is there any signal that is far out of specification
when the ignition switch is at the ON position
and the engine runs?
6 VERIFY CURRENT INPUT SIGNAL STATUS Yes Inspect the sensor and related wiring harnesses, repair or
UNDER TROUBLE CONDITION replace it.
• Inspect the same PIDs as Step 5 while Then go to Step 19.
simulating FREEZE FRAME DATA condition. No Go to the next step.
• Is there any signal which causes drastic
changes?
7 VERIFY CURRENT INPUT SIGNAL STATUS OF Yes Go to the next step.
FRONT HO2S No Visually inspect for any gas leakage between the exhaust
• Access the O2S11 for P2177 PID using the M- manifold and the front HO2S.
MDS. Then go to Step 19.
• Check the PID under following accelerator
pedal condition in NEUTRAL.
• Is the PID reading normal?
— –0.1— 0.1 A when idle
— More than 0.25 mA just after release of
accelerator pedal (lean condition)
01-02–221
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01-02–222
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End Of Sie
DTC P2187[L3 WITH TC]
id010239812500
01-02–223
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01-02–224
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01-02–225
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End Of Sie
DTC P2188[L3 WITH TC]
id010239812600
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(Fuel system related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–226
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01-02–227
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End Of Sie
01-02–228
1871-1U-06B(01-02).fm 229 ページ 2006年3月15日 水曜日 午前10時32分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(HO2S related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY RELATED PENDING CODE OR Yes Go to the applicable DTC inspection.
STORED DTC (See01-02-13 DTC TABLE[L3 WITH TC].)
• Turn the ignition switch to off, then to ON No Go to the next step.
position (Engine off).
• Verify the related PENDING CODE or stored
DTCs.
• Is the DTC P2177 or P2187 also present?
4 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA No Go to FREEZE FRAME DATA DTC inspection.
• Is DTC P2195 on FREEZE FRAME DATA? (See01-02-13 DTC TABLE[L3 WITH TC].)
5 VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to the next step.
• Connect the M-MDS to the DLC-2. No Inspect the malfunctioning part according to the inspection
• Verify the following PIDs. results.
(See01-40-6 PCM INSPECTION[L3 WITH Then go to Step 16.
TC].)
— APP1
— APP2
— ECT
— MAF
— TP
— VSS
• Are the PIDs normal?
01-02–229
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01-02–230
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End Of Sie
DTC P2196[L3 WITH TC]
id010239812800
01-02–231
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01-02–232
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End Of Sie
DTC P2228[L3 WITH TC]
WM: DTC P22XX
id010239812900
01-02–233
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End Of Sie
DTC P2229[L3 WITH TC]
id010239813000
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT BARO SENSOR MALFUNCTION Yes Replace the PCM, then go to the next step.
• Start the engine. No Go to the next step.
• Access the BARO PID using the M-MDS.
• Inspect that the BARO PID is within the
specification.
• Is there any malfunction?
01-02–234
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End Of Sie
DTC P2237[L3 WITH TC]
id010239813100
1C 2Z
1B 2AC
4 6 5
1A 2AD
01-02–235
1871-1U-06B(01-02).fm 236 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
01-02–236
1871-1U-06B(01-02).fm 237 ページ 2006年3月15日 水曜日 午前10時32分
DTC P2245 Front HO2S sensor reference voltage circuit low input
• The PCM monitors is front HO2S sensor reference voltage circuit voltage. If the voltage below the threshold
value while the engine is running, the PCM determines that the front HO2S sensor reference voltage circuit
is low.
Diagnostic support note
DETECTION • This is a continuous monitor (HO2S). 01-02
CONDITION • The MIL illuminates if the PCM detects the above malfunctioning condition in two consecutive drive cycles
or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction conditions during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• Front HO2S malfunction
POSSIBLE • Connector or terminal malfunction
CAUSE • Short to ground circuit between PCM terminal 2Y and front HO2S sensor terminal 2C
• PCM malfunction
FRONT HO2S PCM
4 5 7 6
2C 2Y
4 6
2A 2M
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(HO2S related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA No Go to troubleshooting for DTC on FREEZE FRAME DATA.
• Is DTC P2245 on FREEZE FRAME DATA? (See01-02-13 DTC TABLE[L3 WITH TC].)
01-02–237
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End Of Sie
01-02–238
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DTC P2246 Front HO2S sensor reference voltage circuit high input
• The PCM monitors the front HO2S sensor reference voltage circuit voltage. If the voltage is above the
threshold value while the engine is running, the PCM determines that the front HO2S sensor reference
voltage circuit is high.
Diagnostic support note
DETECTION • This is a continuous monitor (HO2S). 01-02
CONDITION • The MIL illuminates if the PCM detects the above malfunctioning condition in two consecutive drive cycles
or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction conditions during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in the PCM memory.
• Front HO2S malfunction
• Connector or terminal malfunction
POSSIBLE • Short to the power circuit between PCM terminal 2Y and front HO2S terminal 2C
CAUSE • Open circuit between PCM terminal 2Y and front HO2S terminal 2C
• Open circuit between PCM terminal 2M and front HO2S terminal 2A
• PCM malfunction
FRONT HO2S PCM
4 5 6 7
2C 2Y
8
4 7
2A 2M
8
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(HO2S related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA No Go to troubleshooting for DTC on FREEZE FRAME DATA.
• Is DTC P2246 on FREEZE FRAME DATA? (See01-02-13 DTC TABLE[L3 WITH TC].)
01-02–239
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End Of Sie
01-02–240
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5 6
1C 2Z
5 7 6
1B 2AC
5 6
1A 2AD
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA AND Yes Go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS No Record the FREEZE FRAME DATA and DIAGNOSTIC
HAVE BEEN RECORDED MONITORING TEST RESULTS on the repair order, then
• Have the FREEZE FRAME DATA and go to the next step.
DIAGNOSTIC MONITORING TEST RESULTS
(HO2S related) been recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–241
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End Of Sie
WM: DTC P24XX
01-02–242
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DTC P2401 EVAP system leak detection pump motor circuit low
• The PCM monitors the pump load current (EVAP line pressure), while the EVAP leak monitor is operating.
If the pump load current is lower than specified, the PCM determines that the EVAP system leak detection
pump motor circuit has a malfunction.
Diagnostic support note
DETECTION • This is a intermittent monitor (CCM). 01-02
CONDITION • MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in PCM memory.
• EVAP system leak detection pump malfunction
• Open circuit between main relay and EVAP system leak detection pump terminal A
POSSIBLE • Open circuit between EVAP system leak detection pump terminal D and PCM terminal 1AS
CAUSE • Short to ground circuit between EVAP system leak detection pump terminal D and PCM terminal 1AS
• Poor connection at the EVAP system leak detection pump or the PCM connector
• PCM malfunction
5
4
A
4 6
C 1V
9
4 7 6
M D 1AS
8
4
B
01-02–243
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01-02–244
1871-1U-06B(01-02).fm 245 ページ 2006年3月15日 水曜日 午前10時32分
Note
• If EVAP system test function is not
available, take following procedure.
— Start the engine and perform the
“EVAP System Repair Verification
Drive Mode”.
(See01-02-10 OBD-II DRIVE
MODE[L3 WITH TC].)
— Is the PENDING CODE for this DTC
present?
11 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–245
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DTC P2402 EVAP system leak detection pump motor circuit high
• The PCM monitors the pump load current (EVAP line pressure), while the EVAP leak monitor is operating.
If the pump load current is higher than specified, the PCM determines that the EVAP system leak detection
pump motor circuit has a malfunction.
Diagnostic support note
DETECTION • This is a intermittent monitor (CCM).
CONDITION • MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in PCM memory.
• EVAP system leak detection pump malfunction
POSSIBLE • Short to the power supply between the EVAP system leak detection pump terminal D and PCM terminal
CAUSE 1AS
• PCM malfunction
4
A
C 1V
5
M D 1AS
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnostic according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, then go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–246
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Note
• If EVAP system test function is not
available, take following procedure.
End Of Sie
01-02–247
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DTC P2404 EVAP system leak detection pump sensor circuit malfunction
• The PCM monitors the pump load current (EVAP line pressure), while the EVAP leak monitor is operating.
After obtaining the reference current value, If the pump load current is greater than or equal to the
reference current value plus 2 mA within the specified time, the PCM determines that the air filter has a
malfunction.
Diagnostic support note
DETECTION • This is a intermittent monitor (CCM).
CONDITION • MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in PCM memory.
• Air filter clogging
POSSIBLE
• EVAP hose bending
CAUSE
• PCM malfunction
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnostic according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, then go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 CHECK EVAP HOSE BENDING Yes Go to the next step.
• Inspect the EVAP hose for bending. No Repair or replace the suspected hose, then go to Step 5.
• Is the EVAP hose normal?
4 CHECK AIR FILTER FOR CLOGGING Yes Go to the next step.
• Inspect the air filter for clogging. No Replace the air filter, then go to the next step.
• Is the air filter normal?
5 VERIFY TROUBLESHOOTING OF DTC P2404 Yes Replace the PCM, then go to the next step.
COMPLETED No Go to the next step.
• Make sure to reconnect all disconnected
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the EVAP system test using the M-
MDS.
(See01-03-78 ENGINE CONTROL SYSTEM
OPERATION INSPECTION[L3 WITH TC].)
• Is the same DTC present?
Note
• If EVAP system test function is not
available, take following procedure.
— Perform the “EVAP System Repair
Verification Drive Mode”.
(See01-02-10 OBD-II DRIVE
MODE[L3 WITH TC].)
— Is the PENDING CODE for this DTC
present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–248
1871-1U-06B(01-02).fm 249 ページ 2006年3月15日 水曜日 午前10時32分
DTC P2405 EVAP system leak detection pump sensor circuit low input
• The PCM monitors the pump load current (EVAP line pressure), while the EVAP leak monitor is operating.
If the current is lower than the specification while the PCM obtains the reference current value, the PCM
determines that the EVAP system leak detection pump orifice has a malfunction.
Diagnostic support note
DETECTION • This is a intermittent monitor (CCM). 01-02
CONDITION • MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in PCM memory.
• EVAP system leak detection pump orifice has fallen off
POSSIBLE
• EVAP system leak detection pump motor malfunction
CAUSE
• PCM malfunction
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Replace the EVAP system leak detection pump, then go to
• Is any related repair information available? the next step.
3 VERIFY TROUBLESHOOTING OF DTC P2405 Yes Replace the PCM, then go to the next step.
COMPLETED No Go to the next step.
• Make sure to reconnect all disconnected
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the EVAP system test using the M-
MDS.
(See01-03-78 ENGINE CONTROL SYSTEM
OPERATION INSPECTION[L3 WITH TC].)
• Is the same DTC present?
Note
• If EVAP system test function is not
available, take following procedure.
— Start the engine and perform the
“EVAP System Repair Verification
Drive Mode”.
(See01-02-10 OBD-II DRIVE
MODE[L3 WITH TC].)
— Is the PENDING CODE for this DTC
present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR No Troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–249
1871-1U-06B(01-02).fm 250 ページ 2006年3月15日 水曜日 午前10時32分
DTC P2407 EVAP system leak detection pump sensor circuit intermittent
• The PCM monitors pump the load current (EVAP line pressure), while the EVAP leak monitor is operating.
When either of the following is detected6 times or more successively, the PCM determines that the
EVAP system leak detection pump heater has a malfunction:
— While obtaining the reference current value, the change in pump load current exceeds the specification.
— After obtaining the reference current value, the pump load current is kept lower than the maximum pump
load current for more than the specified time.
DETECTION Diagnostic support note
CONDITION • This is a intermittent monitor (CCM).
• MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in
one drive cycle while the DTC for the same malfunction has been stored in the PCM.
• PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
• FREEZE FRAME DATA is available.
• DTCs are stored in PCM memory.
POSSIBLE • EVAP system leak detection pump heater malfunction
CAUSE • PCM malfunction
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT EVAP SYSTEM LEAK DETECTION Yes Replace the EVAP system leak detection pump, then go to
PUMP HEATER the next step.
• Perform the EVAP system leak detection pump No Go to the next step.
inspection.
(See01-16-7 EVAPORATIVE EMISSION
(EVAP) SYSTEM LEAK DETECTION PUMP
INSPECTION[L3 WITH TC])
• Is the EVAP system leak detection pump
normal?
4 VERIFY TROUBLESHOOTING OF DTC P2407 Yes Replace the PCM, then go to the next step.
COMPLETED No Go to the next step.
• Make sure to reconnect all disconnected
connectors.
• Clear the DTC from the PCM memory using
the M-MDS.
• Perform the EVAP system test using the M-
MDS.
(See01-03-78 ENGINE CONTROL SYSTEM
OPERATION INSPECTION[L3 WITH TC].)
• Is the same DTC present?
Note
• If EVAP system test function is not
available, take following procedure.
01-02–250
1871-1U-06B(01-02).fm 251 ページ 2006年3月15日 水曜日 午前10時32分
id010239814000
D 2AI
MAIN RELAY
P 2AJ
1BE
4 6
B
- + 5
BATTERY 3
PCM
GENERATOR WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
B D P
*
1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
01-02–251
1871-1U-06B(01-02).fm 252 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P2503[L3 WITH TC]
id010239814100
01-02–252
1871-1U-06B(01-02).fm 253 ページ 2006年3月15日 水曜日 午前10時32分
5 6 4
D 2AI
8 MAIN RELAY
01-02
5 7 4
P 2AJ
9 4
1BE
5
B
- +
BATTERY
PCM
GENERATOR WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
B D P
*
1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT DRIVE CHAIN CONDITION Yes Go to the next step.
• Verify that the drive chain auto tensioner No Replace the and/or adjust drive chain, then go to Step 10.
indicator mark does not exceed limit.
• Is the front drive chain normal?
4 INSPECT PCM CONNECTOR FOR POOR Yes Repair the terminals, then go to Step 10.
CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the PCM connector.
• Inspect for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
• Is there any malfunction?
5 INSPECT GENERATOR CONNECTOR FOR Yes Repair or replace the terminals, then go to Step 10.
POOR CONNECTION No Go to the next step.
• Disconnect the generator connector.
• Inspect for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
• Is there any malfunction?
01-02–253
1871-1U-06B(01-02).fm 254 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P2504[L3 WITH TC]
id010239814200
01-02–254
1871-1U-06B(01-02).fm 255 ページ 2006年3月15日 水曜日 午前10時32分
4
3 6 7 5
D 2AI
MAIN RELAY
01-02
3 5
P 2AJ
5
1BE
3
B
- +
BATTERY
PCM
GENERATOR WIRING HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
B D P
*
1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT GENERATOR CONNECTOR FOR Yes Repair or replace the terminals, then go to Step 8.
POOR CONNECTION No Go to the next step.
• Turn the ignition switch off.
• Disconnect the generator connector.
• Inspect for poor connection (damaged/pulled-
out terminals, corrosion, etc.).
• Is there any malfunction?
4 CLASSIFY GENERATOR MALFUNCTION OR Yes Go to the next step.
OTHER MALFUNCTION No There is a malfunction at the generator.
• Turn the ignition switch to the ON position Go to Step 7.
(Engine off).
• Measure the voltage between generator
terminal D (wiring harness-side) and body
ground.
• Is the voltage B+?
01-02–255
1871-1U-06B(01-02).fm 256 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P2507[L3 WITH TC]
id010239814300
01-02–256
1871-1U-06B(01-02).fm 257 ページ 2006年3月15日 水曜日 午前10時32分
PCM
WIRING HARNESS SIDE CONNECTOR
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record FREEZE FRAME DATA on the repair order, then go
• Has the FREEZE FRAME DATA been to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Check for related Service Bulletins and/or on- • If the vehicle is not repaired, go to the next step.
line repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT EEC FUSE Yes Go to step 6.
• Turn the ignition switch to off. No • If the EEC fuse has been melt down, then go to the next
• Inspect the EEC fuse for failure and proper. step.
• Is it normal? • If the EEC fuse is not installed correctly, install it
correctly then go to Step 7.
4 INSPECT MONITOR CIRCUIT FOR SHORT TO Yes Repair or replace the wiring harness for a short to ground
GROUND and install new fuse, then go to Step 7.
• Disconnect the battery cables. No Go to step 7.
• Inspect for continuity between EEC fuse
terminal and body ground.
• Is there continuity?
5 INSPECT PCM CONNECTOR FOR POOR Yes Repair the terminals, then go to Step 7.
CONNECTION No Go to the next step.
• Disconnect the PCM connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Is there any malfunction?
6 INSPECT MONITOR CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace the wiring harness for an open circuit,
• Disconnect the battery cables. then go to the next step.
• Inspect for continuity between EEC fuse
terminal and PCM terminal 1BA (harness-
side).
• Is there continuity?
01-02–257
1871-1U-06B(01-02).fm 258 ページ 2006年3月15日 水曜日 午前10時32分
End Of Sie
DTC P2610[L3 WITH TC]
WM: DTC P26XX
id010239814400
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform the repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY TROUBLESHOOTING OF DTC P2610 Yes Replace the PCM, then go to the next step.
COMPLETED (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH
• Make sure to reconnect all the disconnected TC].)
connectors. No Go to the next step.
• Clear the DTC from the PCM memory using
the M-MDS.
• Start the engine.
• Is the same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC troubleshooting.
• Perform the “AFTER REPAIR PROCEDURE”. (See01-02-13 DTC TABLE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[L3 WITH TC].)
• Are any DTCs present?
End Of Sie
01-02–258
1871-1U-06B(01-03).fm 1 ページ 2006年3月15日 水曜日 午前10時36分
End of Toc
01-03–1
1871-1U-06B(01-03).fm 2 ページ 2006年3月15日 水曜日 午前10時36分
id010339800100
c 2BG
FUEL INJECTOR
1AY
2BB NO.1
b
a 1BE FUEL INJECTOR
NO.4
2AZ
1BA
2BH
FUEL INJECTOR
1AZ NO.3
2BD
FUEL INJECTOR
NO.2
2BC
1AR 2BF
IAT SENSOR FUEL INJECTOR RELAY
1M 2BE
MAF 1AK
1AW
SENSOR
1P
2C HO2S HEATER (FRONT)
1Q
HO2S HEATER (REAR)
1AV 2D
APP 1Y
SENSOR 1AE FAN CONTROL MODULE NO.1
1U
1AC
COOLING FAN
RELAY NO.1
1AJ
PCM
1AO b
2P
FUEL PRESSURE SENSOR
2R 1R FAN CONTROL MODULE NO.2
2I
COOLING FAN
2AY RELAY NO.2
ECT SENSOR 1K
2AH
A/C RELAY b
1I
2AV
FUEL PUMP SPEED CONTROL RELAY
MAP 1AA
2AG
SENSOR
2N
BOOST AIR TEMPERATURE
FUEL PUMP RESISTOR
SENSOR 2AU
1BC
HO2S (REAR)
2Q FUEL PUMP RELAY
1H
2M b
1AT
2AD
MAIN RELAY
HO2S
(FRONT) 2AC
STARTER RELAY c
2Z 1B
IGNITION
2Y
SWITCH
DRIVE-BY-WIRE-RELAY
2X
1BF
CKP SENSOR
2W 1AX
BATTERY
CMP SENSOR 2S
f a
d e
acxuuw00002267
01-03–2
1871-1U-06B(01-03).fm 3 ページ 2006年3月15日 水曜日 午前10時36分
d e f
EGR VALVE
2AQ
2AM
2V
KS 01-03
2U 2AR
2AN
2AK
2AP
EVAP SYSTEM LEAK
DETECTION PUMP
TP SENSOR
2AL 1V
b
2AO 1AS
2E
REFRIGERANT PRESSURE SWITCH (HIGH, LOW)
1AU 2B
THROTTLE
REFRIGERANT PRESSURE SWITCH (MIDDLE) 2A
ACTUATOR
1J
2F
PSP SWITCH SPILL VALVE CONTROL
2T
2G
SOLENOID VALVE
2H
1BB
1AQ
1BD
1BH
2AI GENERATOR
acxuuw00002268
End Of Sie
01-03–3
1871-1U-06B(01-03).fm 4 ページ 2006年3月15日 水曜日 午前10時36分
CUSTOMER ARRIVES
acxuuw00002431
01-03–4
1871-1U-06B(01-03).fm 5 ページ 2006年3月15日 水曜日 午前10時36分
End Of Sie
01-03–5
1871-1U-06B(01-03).fm 6 ページ 2006年3月15日 水曜日 午前10時36分
X: Applied
GENERATOR CONTROL
WASTEGATE CONTROL
FUEL PUMP CONTROL
Item
CRUISE CONTROL
EGR CONTROL
ESA CONTROL
CAN
IAC
Input device
IAT sensor X X X X X X X X X
MAF sensor X X X X X X X X X X X X X
TP sensor No.1, No.2 X X X X X X X X
APP sensor No.1,
X X X X X X X X X X
No.2
MAP sensor X X X X X
ECT sensor X X X X X X X X X X X X X
CMP sensor X X X X X
CKP sensor X X X X X X X X X X X X X X X X
KS X
HO2S (front, rear) X X X
BARO sensor X X X X X X X
Neutral switch X X X X X X X X X
CPP switch X X X X X X X X X
Brake switch X X X X
Instrument cluster (A/
X X X
C on request signal)
Refrigerant pressure
switch
X X X
(low pressure switch,
high pressure switch)
Refrigerant pressure
switch (medium X X
pressure switch)
Battery X X X X X X X X X X X
Generator (Terminal
X X
P: starter coil)
Vehicle speed signal X X X X X X X X X
Cruise control switch X
Instrument cluster
X X X X X X X
(CAN signal)
Ignition switch X X X X X X X
Fuel pressure sensor X X X X
Boost air temperature
X X X X X
sensor
Output device
Throttle actuator X X X
Drive-by-wire-relay X
01-03–6
1871-1U-06B(01-03).fm 7 ページ 2006年3月15日 水曜日 午前10時36分
GENERATOR CONTROL
WASTEGATE CONTROL
FUEL PUMP CONTROL
Item
CRUISE CONTROL
EGR CONTROL
ESA CONTROL
CAN
IAC
End Of Sie
01-03–7
1871-1U-06B(01-03).fm 8 ページ 2006年3月15日 水曜日 午前10時36分
X: Applied
Possible factor
Flywheel is seized
Improper dipstick
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates
3 Will not crank x x x x x x
4 Hard start/long crank/erratic start/erratic crank x x x
5 Engine stalls After start/at idle x
6 Cranks normally but will not start x
7 Slow return to idle x x
8 Engine runs rough/rolling idle x
9 Fast/idle runs on
10 Low idle/stalls during deceleration x
Engine stalls/quits Acceleration/cruise x
Engine runs rough Acceleration/cruise x
Misses Acceleration/cruise x
11 Acceleration/cruise/
Buck/jerk deceleration
x
Hesitation/stumble Acceleration/cruise x
Surges Acceleration/cruise x
12 Lack/loss of power Acceleration/cruise x
13 Knocking/pinging Acceleration/cruise x x
14 Poor fuel economy x x x x
15 Emission compliance x x x
16 High oil consumption/leakage x x
17 Cooling system concerns Overheating x x x x x
18 Cooling system concerns Runs cold x x
19 Exhaust smoke x x x
20 Fuel odor (in engine compartment)
21 Engine noise x
22 Vibration concerns (engine)
23 A/C does not work sufficiency
A/C always on or A/C compressor
24
runs continuously.
25 A/C does not cut off under wide open throttle
26 Exhaust sulphur smell
27 Fuel refill concerns
28 Fuel filling shut off issues
29 Spark plug condition x
acxuuw00000310
01-03–8
1871-1U-06B(01-03).fm 9 ページ 2006年3月15日 水曜日 午前10時36分
X: Applied
Possible factor
Engine overheating
Fuel quality
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates x x
3 Will not crank
4 Hard start/long crank/erratic start/erratic crank x x x x x
5 Engine stalls After start/at idle x x x x x
6 Cranks normally but will not start x x x x x x
7 Slow return to idle x
8 Engine runs rough/rolling idle x x x x x
9 Fast/idle runs on x x
10 Low idle/stalls during deceleration x x x
Engine stalls/quits Acceleration/cruise x x x x x x
Engine runs rough Acceleration/cruise x x x x x x
Misses Acceleration/cruise x x x x x x
11 Acceleration/cruise/
Buck/jerk deceleration x x x x x x
Hesitation/stumble Acceleration/cruise x x x x x x
Surges Acceleration/cruise x x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x x x x
13 Knocking/pinging Acceleration/cruise x x x
14 Poor fuel economy x x x
15 Emission compliance x x x x x
16 High oil consumption/leakage x x
17 Cooling system concerns Overheating x
18 Cooling system concerns Runs cold
19 Exhaust smoke x x x x
20 Fuel odor (in engine compartment)
21 Engine noise x
22 Vibration concerns (engine) x x
23 A/C does not work sufficiency
A/C always on or A/C compressor
24
runs continuously.
25 A/C does not cut off under wide open throttle
26 Exhaust sulphur smell x
27 Fuel refill concerns
28 Fuel filling shut off issues
29 Spark plug condition x
acxuuw00000311
01-03–9
1871-1U-06B(01-03).fm 10 ページ 2006年3月15日 水曜日 午前10時36分
X: Applied
Possible factor
or electrically)
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates x
3 Will not crank
4 Hard start/long crank/erratic start/erratic crank x x x x x x x x x
5 Engine stalls After start/at idle x x x x x x x
6 Cranks normally but will not start x x x x x x x x
7 Slow return to idle x x
8 Engine runs rough/rolling idle x x x x x x x
9 Fast/idle runs on x x
10 Low idle/stalls during deceleration x x x x x
Engine stalls/quits Acceleration/cruise x x x x x x x x x x
Engine runs rough Acceleration/cruise x x x x x x x x x x
Misses Acceleration/cruise x x x x x x x x x x
11 Acceleration/cruise/
Buck/jerk deceleration x x x x x x x x x x
Hesitation/stumble Acceleration/cruise x x x x x x x x x x
Surges Acceleration/cruise x x x x x x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x x x x x x x x
13 Knocking/pinging Acceleration/cruise x x x x x x
14 Poor fuel economy x x x x x x x x
15 Emission compliance x x x x x x x x x
16 High oil consumption/leakage x
17 Cooling system concerns Overheating
18 Cooling system concerns Runs cold
19 Exhaust smoke x x x x x
20 Fuel odor (in engine compartment) x x
21 Engine noise x x
22 Vibration concerns (engine)
23 A/C does not work sufficiency
A/C always on or A/C compressor
24
runs continuously.
25 A/C does not cut off under wide open throttle
26 Exhaust sulphur smell x x x
27 Fuel refill concerns
28 Fuel filling shut off issues
29 Spark plug condition x x x x x x
acxuuw00000312
01-03–10
1871-1U-06B(01-03).fm 11 ページ 2006年3月15日 水曜日 午前10時36分
X: Applied
Possible factor
01-03–11
1871-1U-06B(01-03).fm 12 ページ 2006年3月15日 水曜日 午前10時36分
X: Applied
Possible factor
malfunction
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates x x x x x x x x
3 Will not crank x
4 Hard start/long crank/erratic start/erratic crank x x x
5 Engine stalls After start/at idle x x x x x
6 Cranks normally but will not start x x x x
7 Slow return to idle x x
8 Engine runs rough/rolling idle x x x x
9 Fast/idle runs on x
10 Low idle/stalls during deceleration x x x x
Engine stalls/quits Acceleration/cruise x x x x x x
Engine runs rough Acceleration/cruise x x x x x x
Misses Acceleration/cruise x x x x x x
11 Acceleration/cruise/
Buck/jerk deceleration
x x x x x x
Hesitation/stumble Acceleration/cruise x x x x x x
Surges Acceleration/cruise x x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x
13 Knocking/pinging Acceleration/cruise x x x x
14 Poor fuel economy x x x x x
15 Emission compliance x x x x x x
16 High oil consumption/leakage
17 Cooling system concerns Overheating
18 Cooling system concerns Runs cold
19 Exhaust smoke x x x x x
20 Fuel odor (in engine compartment)
21 Engine noise
22 Vibration concerns (engine)
23 A/C does not work sufficiency
A/C always on or A/C compressor
24
runs continuously.
25 A/C does not cut off under wide open throttle
26 Exhaust sulphur smell x
27 Fuel refill concerns x x
28 Fuel filling shut off issues x x
29 Spark plug condition x x x
acxuuw00000314
01-03–12
1871-1U-06B(01-03).fm 13 ページ 2006年3月15日 水曜日 午前10時36分
X: Applied
Possible factor
01-03–13
1871-1U-06B(01-03).fm 14 ページ 2006年3月15日 水曜日 午前10時36分
X: Applied
Possible factor
Suspension malfunction
Drive line malfunction
Improper ATF level
Brake dragging
Loose parts
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates
3 Will not crank x x x
4 Hard start/long crank/erratic start/erratic crank
5 Engine stalls After start/at idle x
6 Cranks normally but will not start x
7 Slow return to idle
8 Engine runs rough/rolling idle
9 Fast/idle runs on
10 Low idle/stalls during deceleration x
Engine stalls/quits Acceleration/cruise x
Engine runs rough Acceleration/cruise x
Misses Acceleration/cruise x
11 Acceleration/cruise/
Buck/jerk deceleration x
Hesitation/stumble Acceleration/cruise x
Surges Acceleration/cruise x
12 Lack/loss of power Acceleration/cruise x x
13 Knocking/pinging Acceleration/cruise
14 Poor fuel economy x x
15 Emission compliance
16 High oil consumption/leakage
17 Cooling system concerns Overheating
18 Cooling system concerns Runs cold
19 Exhaust smoke
20 Fuel odor (in engine compartment)
21 Engine noise x
22 Vibration concerns (engine) x x x x
23 A/C does not work sufficiency x
A/C always on or A/C compressor x
24
runs continuously.
25 A/C does not cut off under wide open throttle
26 Exhaust sulphur smell
27 Fuel refill concerns
28 Fuel filling shut off issues
29 Spark plug condition
acxuuw00000316
End Of Sie
01-03–14
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01-03
01-03–15
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End Of Sie
NO.2 MIL ILLUMINATES[L3 WITH TC]
id010339800800
2 MIL ILLUMINATES
DESCRIPTION MIL illuminates incorrectly.
• PCM illuminates for emission-related concern (DTC is stored in PCM)
• Instrument cluster malfunction
POSSIBLE CAUSE
Note
• If the MIL blinks at a steady rate, a misfire condition could possibly exist.
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC. Yes DTC is displayed:
Turn the ignition switch to the ON position. • Go to the appropriate DTC test.
Retrieve any DTCs. (See01-02-13 DTC TABLE[L3 WITH TC].)
Is a DTC displayed? No No DTC is displayed:
• Inspect for an open or short to circuit between
instrument cluster terminal 2T and PCM terminal
1AI
• Inspect for an open or short to circuit between
instrument cluster terminal 2R and PCM terminal
1AM
(See09-22-3 INSTRUMENT CLUSTER
INSPECTION.)
2 Verify test results.
• If normal, return to the diagnostic index to service any additional symptoms.
• If a malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform the
repair or diagnosis.
— If the vehicle is repaired, troubleshooting is completed.
— If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if a later
calibration is available. Retest.
End Of Sie
01-03–16
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
SYMPTOM TROUBLESHOOTING [L3 WITH TC]
NO.3 WILL NOT CRANK[L3 WITH TC]
id010339800900
End Of Sie
01-03–19
1871-1U-06B(01-03).fm 20 ページ 2006年3月15日 水曜日 午前10時36分
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
01-03–20
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01-03–21
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End Of Sie
01-03–22
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
SYMPTOM TROUBLESHOOTING [L3 WITH TC]
NO.5 ENGINE STALLS-AFTER START/AT IDLE[L3 WITH TC]
id010339801100
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
01-03–23
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
SYMPTOM TROUBLESHOOTING [L3 WITH TC]
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC-2. Yes Both conditions are appear:
Do any of the following conditions appear? Go to Step 5.
• Engine does not start completely. No Either or other condition appears:
• DTC B1681 is displayed. Go to the next step.
2 Does the engine stall after approx. 2s from Yes Go to the next step.
when it is started? No Is the immobilizer system is normal?
Go to Step 16.
3 Is the coil connector securely connected to coil? Yes Go to the next step.
No Connect the connector securely, retest from Step 2.
4 Does the security light illuminate? Yes Go to the next step.
No Inspect and repair or replace the following:
• Instrument cluster
(See09-22-3 INSTRUMENT CLUSTER
INSPECTION.)
With advanced keyless entry system
• Between keyless CM 3X and instrument cluster 2R
• Between keyless CM 3W and instrument cluster 2T
Without advanced keyless entry system
• Between PCM 1AM and instrument cluster 2R
• Between PCM 1AI and instrument cluster 2T
5 Retrieve the DTC using the M-MDS. Yes Go to appropriate DTC test.
Are any of the following DTCs present? (See09-02B-3 DTC TABLE[IMMOBILIZER SYSTEM
DTC B1213, B1342, B1600, B1601, B1602, (ADVANCED KEYLESS SYSTEM)])
B1681, B2103, B2431 No Go to the next step.
6 Is there continuity between PCM terminal 1BD, Yes Go to the next step.
1AZ, 1BH and ground? No Repair or replace the wiring harness.
7 Turn the ignition switch to the ON position Yes Go to the next step.
(Engine off.) No Repair or replace the wiring harness.
Measure the voltage between PCM terminal
1BD, 1AZ, 1BH and ground.
Is the voltage below 1.0V?
8 Turn the ignition switch to the ON position. Yes Go to the next step.
(Engine off) No Repair or replace the wiring harness.
Access the VPWR PID.
Is the VPWR PID normal?
VPWR PID
Battery voltage
9 Disconnect the coil connector. Yes Go to the next step.
Turn the ignition switch to the ON position. No Repair or replace the wiring harness between coil
(Engine off) connector terminal D and the fuse panel.
Is there battery voltage at coil connector terminal
D?
10 Inspect the following wiring harness and Yes Repair or replace malfunction part.
connectors. No With advanced keyless entry system
With advanced keyless entry system Go to the next step.
• Between coil terminal A and keyless CM Without advanced keyless entry system
terminal 3U Go to Step 14.
• Between coil terminal B and keyless CM
terminal 3V
Without advanced keyless entry system
• Between coil terminal A and instrument
cluster 2Q
• Between coil terminal B and instrument
cluster 2S
Is there any malfunction (open or short circuit,
terminal corrosion, etc.)?
11 Is there continuity between the keyless CM Yes Go to the next step.
harness-side connector terminal 2B and body No Repair or replace the wiring harness.
ground?
12 Turn the ignition switch to the ON position. Yes Go to the next step.
Measure the voltage between keyless CM No Repair or replace the wiring harness.
harness-side connector terminal 2B and body
ground.
Is the voltage below 1.0V?
01-03–26
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End Of Sie
01-03–27
1871-1U-06B(01-03).fm 28 ページ 2006年3月15日 水曜日 午前10時36分
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
01-03–28
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
SYMPTOM TROUBLESHOOTING [L3 WITH TC]
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC-2. Yes Both conditions are appear:
Do any of the following conditions appear? Go to Step 5.
• Engine does not completely start. No Either or other condition appears:
• DTC B1681 is displayed. Go to the next step.
2 Does the engine stall after approx. 2s from Yes Go to the next step.
when it is started? No Is the Is the immobilizer system is normal. 01-03
Go to Step 20.
3 Is the coil connector securely connected to coil? Yes Go to the next step.
No Connect the connector securely, retest from Step 1.
4 Does the security light illuminate? Yes Go to the next step.
No Inspect and repair or replace the following:
• Instrument cluster
(See09-22-3 INSTRUMENT CLUSTER
INSPECTION.)
With advanced keyless entry system
• Between keyless CM 3X and instrument cluster 2R
• Between keyless CM 3W and instrument cluster 2T
Without advanced keyless entry system
• Between PCM 1AM and instrument cluster 2R
• Between PCM 1AI and instrument cluster 2T
5 Retrieve the DTC using the M-MDS. Yes Go to appropriate DTC test.
Are any of the following DTCs present? (See09-02B-3 DTC TABLE[IMMOBILIZER SYSTEM
DTC (ADVANCED KEYLESS SYSTEM)].)
B1213, B1342, B1600, B1601, B1602, B1681, No Go to the next step.
B2103, B2431
6 Is there continuity between PCM terminal 1BD, Yes Go to the next step.
1AZ, 1BH and ground? No Repair or replace the wiring harness.
7 Turn the ignition switch to the ON position Yes Go to the next step.
(Engine off.) No Repair or replace the wiring harness.
Measure the voltage between PCM terminal
1BD, 1AZ, 1BH and ground.
Is the voltage below 1.0V?
8 Turn the ignition switch to the ON position. Yes Go to the next step.
(Engine off) No Repair or replace the wiring harness.
Access the VPWR PID.
Is the VPWR PID normal?
VPWR PID
Battery voltage
9 Disconnect the coil connector. Yes Go to the next step.
Turn the ignition switch to the ON position. No Repair or replace the wiring harness between coil
(Engine off) connector terminal D and the fuse panel.
Is there battery voltage at coil connector terminal
D?
10 Inspect the following wiring harness and Yes Repair or replace malfunctioning part.
connectors. No With advanced keyless entry system
With advanced keyless entry system Go to the next step.
• Between coil terminal A and keyless CM Without advanced keyless entry system
terminal 3U
Go to Step 14.
• Between coil terminal B and keyless CM
terminal 3V
Without advanced keyless entry system
• Between coil terminal A and instrument
cluster 2Q
• Between coil terminal B and instrument
cluster 2S
Is there any malfunction (open or short circuit,
terminal corrosion, etc.)?
11 Is there continuity between the keyless CM Yes Go to the next step.
harness-side connector terminal 2B and body No Repair or replace the wiring harness.
ground?
12 Turn the ignition switch to the ON position. Yes Go to the next step.
Measure the voltage between keyless CM No Repair or replace the wiring harness.
harness-side connector terminal 2B and body
ground.
Is the voltage below 1.0V?
01-03–31
1871-1U-06B(01-03).fm 32 ページ 2006年3月15日 水曜日 午前10時36分
End Of Sie
NO.7 SLOW RETURN TO IDLE[L3 WITH TC]
id010339801300
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Inspect air suction in intake-air system Yes Repair or replace as necessary.
components while racing engine to higher No Go to the next step.
speed.
Is any air suction?
01-03–32
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01-03–33
1871-1U-06B(01-03).fm 34 ページ 2006年3月15日 水曜日 午前10時36分
End Of Sie
NO.8 ENGINE RUNS ROUGH/ROLLING IDLE[L3 WITH TC]
id010339801400
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
01-03–34
1871-1U-06B(01-03).fm 35 ページ 2006年3月15日 水曜日 午前10時36分
01-03–35
1871-1U-06B(01-03).fm 36 ページ 2006年3月15日 水曜日 午前10時36分
End Of Sie
01-03–36
1871-1U-06B(01-03).fm 37 ページ 2006年3月15日 水曜日 午前10時36分
9 FAST IDLE/RUNS ON
• Engine speed continues at fast idle after warm-up.
DESCRIPTION
• Engine runs after the ignition switch is turned off.
• ECT sensor or related circuit malfunction
• Suction control valve (built-in high pressure fuel pump)
• Fuel injector malfunction 01-03
• Air leakage from intake-air system
• Throttle body malfunction
• Accelerator pedal position sensor or related circuit malfunction
• Cruise control system operation improperly
• Improper load signal input
• Improper operation of electric throttle control system
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
POSSIBLE CAUSE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
01-03–37
1871-1U-06B(01-03).fm 38 ページ 2006年3月15日 水曜日 午前10時36分
End Of Sie
01-03–38
1871-1U-06B(01-03).fm 39 ページ 2006年3月15日 水曜日 午前10時36分
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Does the engine idle rough? Yes Go to symptom troubleshooting “NO.8 ENGINE RUNS
ROUGH/ROLLING IDLE”.
(See01-03-34 NO.8 ENGINE RUNS ROUGH/
ROLLING IDLE[L3 WITH TC].)
No Go to the next step.
2 Verify the following: Yes Go to the next step.
• Fuel quality (proper octane, contamination, No Service if necessary. Repeat Step 2.
winter/summer blend)
• Intake-air system restriction or leakage
• Fuel leakage in fuel system
• Vacuum leakage
Are all items normal?
01-03–39
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01-03–40
1871-1U-06B(01-03).fm 41 ページ 2006年3月15日 水曜日 午前10時36分
End Of Sie
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE,
SURGES[L3 WITH TC]
id010339801700
01-03–41
1871-1U-06B(01-03).fm 42 ページ 2006年3月15日 水曜日 午前10時36分
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
01-03–42
1871-1U-06B(01-03).fm 43 ページ 2006年3月15日 水曜日 午前10時36分
01-03–43
1871-1U-06B(01-03).fm 44 ページ 2006年3月15日 水曜日 午前10時36分
Note
• Inspect all fins on each turbine wheel.
01-03–44
1871-1U-06B(01-03).fm 45 ページ 2006年3月15日 水曜日 午前10時36分
End Of Sie
01-03–45
1871-1U-06B(01-03).fm 46 ページ 2006年3月15日 水曜日 午前10時36分
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
01-03–46
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01-03–47
1871-1U-06B(01-03).fm 48 ページ 2006年3月15日 水曜日 午前10時36分
01-03–48
1871-1U-06B(01-03).fm 49 ページ 2006年3月15日 水曜日 午前10時36分
End Of Sie
01-03–49
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13 KNOCKING/PINGING
Sound is produced when air/fuel mixture is ignited by something other than a spark plug (e.g., hot spot in
DESCRIPTION
the combustion chamber).
• Poor fuel quality
• Engine overheating due to cooling system malfunction
• Variable swirl valve stuck closed
• Improper operation of electronic throttle system
• Air leakage or restriction from intake-air system
• ECT sensor or related circuit malfunction
• MAF sensor or related circuit malfunction
• IAT sensor No.1 or related circuit malfunction
• IAT sensor No.2 or related circuit malfunction
• Incorrect fuel injection timing or amount
• Fuel injector malfunction
• Knock sensor or related circuit malfunction
• Ignition system malfunction
• Erratic signal from CMP sensor
• Inadequate engine compression
• Inadequate fuel pressure (high-pressure side)
• Manifold absolute pressure (MAP) sensor or related malfunction
• Wastegate valve malfunction (stuck closed)
• Charge air cooler malfunction
• Fuel pressure sensor or related circuit malfunction
• Accelerator position sensor or related circuit malfunction
POSSIBLE CAUSE • Suction control valve malfunction (built-in high pressure fuel pump)
• Exhaust system and/or three-way catalytic converter (TWC) restriction
• EGR system malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
01-03–50
1871-1U-06B(01-03).fm 51 ページ 2006年3月15日 水曜日 午前10時36分
01-03–51
1871-1U-06B(01-03).fm 52 ページ 2006年3月15日 水曜日 午前10時36分
End Of Sie
01-03–52
1871-1U-06B(01-03).fm 53 ページ 2006年3月15日 水曜日 午前10時36分
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
01-03–53
1871-1U-06B(01-03).fm 54 ページ 2006年3月15日 水曜日 午前10時36分
01-03–54
1871-1U-06B(01-03).fm 55 ページ 2006年3月15日 水曜日 午前10時36分
End Of Sie
01-03–55
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15 EMISSION COMPLIANCE
DESCRIPTION Fails emissions test.
• Poor fuel quality
• Vacuum lines leakage or blockage
• Cooling system malfunction
• Engine overheating
• Spark plug malfunction
• Air leakage from intake-air system
• Variable swirl system malfunction
• Wastegate control system improper operation
• Turbocharger malfunction
• Charge air cooler malfunction
• Inadequate fuel pressure (high-pressure side)
• PCV valve malfunction or incorrect valve installation
• EGR system malfunction
• Exhaust system and/or three-way catalytic converter restriction
• Fuel tank ventilation system malfunction
• Charcoal canister damage
• Air cleaner element clogging or restriction
• Throttle body malfunction
• Improper operation of electronic throttle control system
• Relief valve malfunction (built-in delivery pipe)
• Suction control valve malfunction (built-in high pressure fuel pump)
• Improper air/fuel mixture ratio control operation
• Erratic or no signal from CMP sensor
• Erratic signal from CKP sensor
• Front or rear HO2S or related circuit malfunction
• ECT or related circuit malfunction
• MAF sensor or related circuit malfunction
• IAT sensor No.1 or related circuit malfunction
• IAT sensor No.2 or related circuit malfunction
• Fuel pressure sensor or related circuit malfunction
POSSIBLE CAUSE • Accelerator position sensor or related circuit malfunction
• TP sensor or related circuit malfunction
• Manifold absolute pressure (MAP) sensor or related circuit malfunction
• VSS or related circuit malfunction
• Fuel line restriction
• High pressure fuel pump malfunction
• Fuel injector or related circuit malfunction
• Incorrect fuel injection timing
• Three-way catalytic converter (TWC) malfunction
• Engine internal parts malfunction
• Excessive carbon is built-up in combustion chamber
• Improper engine compression
• Improper valve timing
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
01-03–56
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01-03–58
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Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Remove and shake the PCV valve. Yes Go to the next step.
Does the PCV valve rattle? No Replace the PCV valve.
2 Verify the following: Yes Go to the next step.
• Proper dipstick No Service if necessary.
• Proper engine oil viscosity Repeat Step 2.
• Engine oil level
Are all items normal?
3 Inspect the oil leakage from outside of the Yes Repair or replace oil leakage part.
engine. No Go to the next step.
Is there any oil leakage found?
4 Remove the parts to necessary to inspect Yes Excessive amount of oil is found:
turbocharger without removing the turbocharger. Replace the turbocharger.
Visually inspect for the oil leakage inside Small amount of oil is found:
turbocharger compressor and turbine housing. Wipe oil out of vehicle, then go to the next step.
Is any engine oil found inside turbocharger No Go to the next step.
compressor or turbine housing?
5 Is any engine oil found around oil pipes attached Yes If oil leaks from damaged pipe, replace oil pipe.
on turbocharger center housing? Install the removed parts at Step 4.
No Inspect internal engine parts such as valves, valve
guides, valve stem seals, cylinder head drain passage,
and piston rings.
Then install the removed parts at Step 4.
6 Verify test results.
• If normal, return to the diagnostic index to service any additional symptoms.
• If a malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform the
repair or diagnosis.
— If the vehicle is repaired, troubleshooting is completed.
— If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if a later
calibration is available. Retest.
End Of Sie
01-03–59
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Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Inspect for the following: Yes Go to the next step.
• Engine coolant level No Service if necessary.
• Coolant leakage (around heater unit in Repeat Step 1.Service if necessary.
passenger compartment, coolant hoses and/
or radiator.)
• Water and anti-freeze mixture
• Radiator condition
• Collapsed or restricted radiator hoses
• Radiator pressure cap
• Coolant overflow system
• Fan rotational direction
• Fan rotation direction
• Fuses
Are all items normal?
2 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to appropriate DTC test.
(Engine off). No No DTC is displayed:
Retrieve any DTCs. Go to the next step.
Is there any DTCs displayed?
3 Perform the KOEO and KOER self-test function Yes DTC is displayed:
using the M-MDS. Go to appropriate DTC test.
(See01-02-10 KOEO/KOER SELF TEST[L3 No No DTC is displayed: Go to the next step.
WITH TC].)
Is there any DTCs displayed?
4 Start the engine and run it at idle speed. Yes Go to the next step.
Turn the A/C switch off. No Go to symptom troubleshooting “NO.24 A/C ALWAYS
Does the A/C compressor disengaged? ON OR A/C COMPRESSOR RUNS CONTINUOUSLY.”
(See01-03-69 NO.24 A/C IS ALWAYS ON OR A/C
COMPRESSOR RUNS CONTINUOUSLY[L3 WITH
TC].)
5 Perform the Cooling Fan Control System Yes Go to the next step.
Operation Inspection. No Repair or replace malfunctioning part, according to
(See01-03-78 ENGINE CONTROL SYSTEM inspection results.
OPERATION INSPECTION[L3 WITH TC].)
Does the cooling fan system operate properly?
6 Is the drive belt normal? Yes Go to the next step.
No Replace the drive belt.
7 Is there any leakage around heater unit in Yes Inspect and service heater unit for leakage.
passenger compartment? No Go to the next step.
8 Is there any leakage at coolant hoses and/or Yes Replace the malfunctioning part.
radiator? No Go to the next step.
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End Of Sie
NO.18 COOLING SYSTEM CONCERNS-RUNS COLD[L3 WITH TC]
id010339802400
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Is customer complaint “Lack of passenger Yes Inspect the A/C heater system.
compartment heat” only? No Go to the next step.
2 Does the engine speed continue at fast idle? Yes Go to symptom troubleshooting “NO.9 FAST IDLE/
RUNS ON.”
(See01-03-37 NO.9 FAST IDLE/RUNS ON[L3 WITH
TC].)
No Go to the next step.
3 Cool down the engine. Yes Go to the next step.
Remove the thermostat and inspect operation. No Replace the thermostat.
(See01-12-11 THERMOSTAT REMOVAL/
INSTALLATION[L3 WITH TC].)
(See01-12-11 THERMOSTAT INSPECTION[L3
WITH TC].)
Is thermostat normal?
4 Perform the Cooling Fan Control System Yes Access the ECT PID using the M-MDS.
Operation Inspection. Inspect for both ECT PID and temperature gauge
(See01-03-78 ENGINE CONTROL SYSTEM readings.
OPERATION INSPECTION[L3 WITH TC].) If the temperature gauge on instrument cluster
Does the cooling fan system operate properly? indicates normal but ECT PID is not same as
temperature gauge reading, inspect the ECT sensor.
(See01-40-25 ENGINE COOLANT TEMPERATURE
(ECT) SENSOR INSPECTION[L3 WITH TC].)
If the temperature gauge on instrument cluster
indicates overheating but ECT PID is normal, inspect
the instrument cluster.
(See09-22-3 INSTRUMENT CLUSTER INSPECTION.)
No Repair or replace malfunctioning part, according to
inspection results.
01-03–61
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End Of Sie
NO.19 EXCESSIVE BLACK SMOKE[L3 WITH TC]
id010339802500
19 EXHAUST SMOKE
DESCRIPTION Blue, black, or smoke from the exhaust system
Blue smoke (Burning oil):
• PCV valve malfunction
• Engine internal oil leakage
• Oil leakage at the compressor or turbine end of the turbocharger
White smoke (Water in combustion):
• Cooling system malfunction (coolant loss)
• Engine internal coolant leakage
• Coolant leakage at the compressor or the turbine end of the turbocharger
Black smoke (Rich fuel mixture):
• Air cleaner restriction
• Intake-air system is collapsed or restricted
• Leakage at engine intake or exhaust manifold
• Wastegate valve malfunction (stuck open)
• Excessive fuel pressure
• Improper engine compression
• Ignition system malfunction
• Improper fuel injection timing and amount
POSSIBLE CAUSE
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 What color is smoke coming from the exhaust Blue Burning oil is indicated.
system? Go to the next step.
White Water in combustion is indicated.
Go to the Step 5.
Black Rich fuel mixture is indicating.
Go to the Step 6.
2 Remove and shake the PCV valve. Yes Go to the next step.
Does the PCV valve rattle? No Replace the PCV valve.
01-03–62
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01-03–63
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End Of Sie
01-03–64
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Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
POSSIBLE CAUSE keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Visually inspect fuel leakage at fuel line. Yes Service if necessary.
Is there any fuel leakage? No Go to the next step.
2 Inspect the vacuum hose routine. Yes Go to the next step.
(See01-13-4 VACUUM HOSE ROUTING No Reconnect the vacuum hose.
DIAGRAM[L3 WITH TC].)
Are vacuum hoses routines properly?
3 Perform the Evaporative Emission (EVAP) Yes Repair or replace suspected part according to the
System Leak Inspection. inspection results.
(See01-03-78 ENGINE CONTROL SYSTEM No Go to the next step.
OPERATION INSPECTION[L3 WITH TC].)
Is there any problem found?
4 Inspect the airflow of purge solenoid valve. Yes Go to the next step.
(See01-16-9 PURGE SOLENOID VALVE No Replace the purge solenoid valve.
INSPECTION[L3 WITH TC].)
Is the purge solenoid airflow properly?
5 Connect the M-MDS to the DLC-2. Yes Inspect the charcoal canister for fuel saturation.
Access the FUEL_PRESPID. If excess amount of liquid fuel is present, replace the
Monitor the FUEL_PRES PID while idle and race charcoal canister.
the engine. No Inspect the fuel pressure sensor and the high pressure
Is the FUEL_PRES PID indicate15 MPa {153 fuel pump.
kgf/cm2, 2175 psi} or less? (See01-40-35 FUEL PRESSURE SENSOR
INSPECTION[L3 WITH TC].)
(See01-14-19 HIGH PRESSURE FUEL PUMP
INSPECTION[L3 WITH TC].)
5 Verify test results.
• If normal, return to the diagnostic index to service any additional symptoms.
• If a malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform the
repair or diagnosis.
— If the vehicle is repaired, troubleshooting is completed.
— If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if a later
calibration is available. Retest.
End Of Sie
01-03–65
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21 ENGINE NOISE
DESCRIPTION Engine noise under hood
Squeal, click or chirp noise:
• Improper engine oil level
• Loose installation of solenoid valves
• Improper drive belt tension
Rumble or grinding sound noise:
• Loose parts
• Fluid revel low or air in power the steering fluid
• Improper drive belt tension
Hiss sound noise:
• Vacuum leakage
• Loose spark plug
• Air leakage from the intake-air system
Rattle noise:
• Loose parts
Rap or roar noise:
• Exhaust system looseness
Excessive noise from turbocharger:
• Foreign objects or material in the compressor inlet to the intake manifold ducting or the compressor
housing
• Carbon built-up in the turbine housing
• Turbocharger routing assembly banding or dragging
• Loose intake or exhaust ducting systems
POSSIBLE CAUSE Other noise:
• Camshaft friction gear noise or MLA noise
• Timing chain noise
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and
repair procedures. Read the following warnings before performing the fuel system
services:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR ROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Is the noise from the turbocharger? Yes Go to Step 8.
No Go to the next step
2 Is squeal, click or chirp sound present? Yes Inspect the engine oil level, solenoid valves installation
or drive belt tension.
No Go to the next step.
3 Is rumble or grinding sound present? Yes Inspect and repair the following;
• Drive belt tension
• Loose parts in engine compartment
• Power steering system fluid level
If normal, perform the power steering fluid line air
bleed.
(See06-14-3 AIR BLEEDING.)
No Go to the next step.
4 Is rattle sound present? Yes Inspect the location of rattle for loose parts.
No Go to the next step.
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End Of Sie
NO.22 VIBRATION CONCERNS (ENGINE)[L3 WITH TC]
id010339802800
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Inspect the following components for loose Yes Inspect the following systems:
attaching bolts or worn parts: • Wheels
• Cooling fan • Transmission and mounts
• Condenser fan • Driveline
• Drive belt and pulley • Suspension
• Engine mounts Service if necessary.
• Exhaust system No Readjust or retighten suspect parts installation
Are all items normal? position.
Service if necessary for other parts.
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End Of Sie
NO.23 A/C DOES NOT WORK SUFFICIENTLY[L3 WITH TC]
id010339802900
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC test.
(Engine off). No No DTC is displayed:
Retrieve any DTCs. Go to the next step.
Are there any DTCs displayed?
2 Disconnect the A/C compressor connector. Yes Inspect for the ground condition of magnetic clutch on
Start the engine and turn the A/C switch on. A/C compressor.
Is there correct voltage at terminal of A/C If ground condition is normal, inspect for an open circuit
compressor magnetic clutch connector? magnetic clutch coil.
Specification No Go to the next step.
10.5 V or more
3 Disconnect the refrigerant pressure switch Yes Inspect the refrigerant pressure switch operation.
connector. If switch is normal, go to the next step.
Connect jumper wire between terminals of A/C No Inspect for the following:
high-pressure switch connector. • A/C switch is stuck open.
Connect jumper wires between terminals of • Open circuit between refrigerant pressure switch
refrigerant pressure switch connector. and PCM terminal 1AC
Turn the ignition switch to the ON position. • Open circuit between blower motor fan switch and
Turn A/C switch on and set blower fan to any resistor (if blower motor does not operate)
speed. • Evaporator temperature sensor and A/C amplifier
Does A/C work?
4 Remove jumper wire from switch connector. Yes Inspect the whether A/C relay is stuck open.
Reconnect connector to refrigerant pressure Replace if necessary.
switch. No Inspect the following and repair or replace if necessary:
Start engine and turn A/C switch on. • Refrigerant charging amount
Does fan operate? • A/C compressor for seizure
5 Verify test results.
• If normal, return to the diagnostic index to service any additional symptoms.
• If a malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform the
repair or diagnosis.
— If the vehicle is repaired, troubleshooting is completed.
— If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if a later
calibration is available. Retest.le. Retest.
End Of Sie
01-03–68
1871-1U-06B(01-03).fm 69 ページ 2006年3月15日 水曜日 午前10時36分
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC test.
(Engine off). No No DTC is displayed:
Retrieve any DTCs. Go to the next step.
Are there any DTCs displayed?
2 Start the engine and idle it. Yes Inspect for the following:
Turn the A/C switch on. • A/C relay is stuck closed.
Remove the A/C relay. • Short to ground circuit between A/C relay and PCM
Does the A/C magnetic clutch disengage? terminal 1I.
If both items normal, go to the next step.
No Inspect if circuit between A/C relay and magnetic clutch
shorts to battery power circuit.
If circuit is normal, inspect magnetic clutch for stuck
engagement or clearance.
3 Disconnect the refrigerant pressure switch Yes Inspect for a short to ground circuit between refrigerant
connector. pressure switch and PCM terminal 1AU.
Start the engine and turn the A/C switch on. No Go to the next step.
Note
• A/C should not work when disconnecting
connector. If A/C remains working, short
to ground circuit may be present.
End Of Sie
01-03–69
1871-1U-06B(01-03).fm 70 ページ 2006年3月15日 水曜日 午前10時36分
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Does the A/C compressor disengage when A/C Yes Go to the next step.
switch is turned off? No Go to symptom troubleshooting “No.24 A/C is always
on or A/C compressor runs continuously”.
2 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to appropriate DTC test.
(Engine off). No No DTC is displayed:
Retrieve any DTCs. Inspect the accelerator position sensor.
Are there any DTCs displayed?
3 Verify test results.
• If normal, return to the diagnostic index to service any additional symptoms.
• If a malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform the
repair or diagnosis.
— If the vehicle is repaired, troubleshooting is completed.
— If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if a later
calibration is available. Retest.le. Retest.
End Of Sie
NO.26 EXHAUST SULPHUR SMELL[L3 WITH TC]
id010339803200
Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair
procedures. Read following warnings before servicing fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
POSSIBLE CAUSE • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See 01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See 01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Are any driveability or exhaust smoke concerns Yes Go to the appropriate flow chart.
present? No Go to the next step.
2 Inspect for the following: Yes Go to the next step.
• Electrical connections No Service if necessary.
• Vacuum lines Repeat Step 2.
• Fuel quality
Are all items normal?
01-03–70
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End Of Sie
NO.27 FUEL REFILL CONCERNS[L3 WITH TC]
id010339803300
Warning
• The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before servicing the fuel system:
— Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
POSSIBLE — Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
CAUSE death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of foreign
material.
01-03–71
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End Of Sie
NO.28 FUEL FILLING SHUT OFF ISSUES[L3 WITH TC]
id010339803400
Warning
• The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before servicing the fuel system:
— Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
POSSIBLE
— Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
CAUSE
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of foreign
material.
Diagnostic procedure
STEP INSPECTION ACTION
1 Connect the M-MDS to the DLC-2. Yes DTC is displayed:
Turn the ignition switch to the ON position Go to the appropriate DTC test.
(Engine off). No No DTC is displayed:
Retrieve any DTCs. Go to the next step.
Are there any DTCs displayed?
2 Remove the fuel-filler pipe. Yes Inspect for the following:
Make sure nonreturn valve is installed properly. • Improper use of fuel nozzle
Inspect the nonreturn valve operation. • Fuel is not inserted correctly.
Is nonreturn valve normal? • Inspect fuel shut-off valve.
No Nonreturn valve is installed improperly:
• Reinstall the nonreturn valve to proper position.
Nonreturn valve does not operate properly:
• Replace the nonreturn valve.
01-03–72
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Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before servicing the fuel system:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete
“BEFORE REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this
manual.
(See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
(See01-14-4 AFTER REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly
cause damage to the fuel pipe and quick release connector. Always clean the quick release
connector joint area before disconnecting/connecting, and make sure that it is free of
foreign material.
Diagnostic procedure
STEP INSPECTION RESULTS ACTION
1 Remove all the spark plugs. Yes Troubleshooting completed.
Inspect the spark plug condition. No Specific plug is wet or covered with carbon:
Is the spark plug condition normal? Go to the next step.
Specific plug looks grayish white:
Go to Step 9.
All plugs are wet or covered with carbon:
Go to Step 11.
All plugs look grayish white:
Go to Step 19.
2 Is the spark plug wet/covered with carbon from Yes Inspect all areas related to oil.
engine oil? No Go to the next step.
01-03–73
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01-03–74
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End Of Sie
01-03–75
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Note
• If engine starts and runs, perform the following steps during idle.
acxuuw00002361
acxuuw00002362
01-03–76
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Note
• If the engine starts and runs, perform the following steps during idle.
3. Access the PIDs for the switch you are inspecting. 01-03
4. Shake the sensor slightly with your finger.
• If the PID value is unstable or a malfunction occurs, check for a poor connection or a poorly mounted
sensor or both.
Note
• If engine starts and runs, perform the following steps during idling.
3. Prepare the output state control function for actuators or relays that you are inspecting.
4. Shake the actuator or relay with your finger for 3 s
after the output state control function is activated.
• If a variable click sound is heard, check for a
poor connection or a poorly mounted actuator
or both, or the relay.
Note
• Shake the relays too strongly may result in
open circuits.
acxuuw00002368
Caution
• Indirectly change the temperature and humidity by spraying water onto the front of the radiator.
• If a vehicle is subject to water leakage, the leakage may damage the control module. When testing
a vehicle with a water leakage problem, special caution must be used.
1. Connect the M-MDS to the DLC-2 if you are inspecting sensors or switches.
2. Turn the ignition switch to the ON position (Engine off).
Note
• If the engine starts and runs, perform the following steps is idling.
3. Access the PIDs for the sensor or the switch if you are inspecting sensors or switches.
4. If you are inspecting the switch, turn it on manually.
5. Spray water onto the vehicle or run it through a
car wash.
• If the PID value is unstable or a malfunction
occurs, repair or replace parts if necessary.
End Of Sie
acxuuw00001941
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Caution
• Compare the M-MDS monitor voltage with the measurement voltage using the digital
measurement system function. If you use another tester, a misreading may occur.
• When measuring the voltage, attach the tester ground to the ground of the PCM that is being
tested, or to the engine itself. If this is not done, the measured voltage and actual voltage may
differ
• After connecting the pin to a waterproof coupler, confirm continuity and measure the voltage, and
inspect the waterproof connector for cracks. If there are any, use sealant to fix them. Failure to do
this may result in deterioration of the wiring harness or terminal from water damage, leading to
problems with the vehicle.
PCM
VREF 4 3
INPUT 1 2
GND 6 5
acxuuw00002364
01-03–78
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Variable resistance type 2 (fuel tank level sensor and mass air flow (MAF) sensor)
PCM
INPUT 1 2
GND 5 4
acxuuw00002365
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PCM
INPUT 1 2
GND 4 3
acxuuw00002366
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PCM
INPUT 1 2
01-03
3
acxuuw00002367
1. Measure the #1 PCM terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch to the ON
position and the engine is idling.
• If it is at 0 V or 5 V, intermittent concern exists. (See01-03-76 INTERMITTENT CONCERN
TROUBLESHOOTING[L3 WITH TC].)
• If not, inspect the following points concerning the PCM connector.
• If there is no problem, inspect for the following:
— Female terminal opening is loose.
— Coupler (pin holder) damage
— Pin discoloration (blackness)
— Wiring harness/pin crimp is loose or disconnected.
2. Measure the #2 sensor terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch to the ON
position and the engine is idling.
• If it is at 0 V or 5 V, intermittent concern exists. (See01-03-76 INTERMITTENT CONCERN
TROUBLESHOOTING[L3 WITH TC].)
• If not, inspect the following points concerning the sensor connector:
• If there is no problem, inspect for the following.
— Female terminal opening is loose.
— Coupler (pin holder) damage
— Pin discoloration (blackness)
— Wiring harness/pin crimp is loose or disconnected.
3. Confirm that the #3 terminal switch voltage is at 0 V.
• If it is at 0 V, inspect the sensor. If necessary, replace the sensor.
— If necessary, replace the sensor.
• If not, inspect for the following:
— Open circuit in wiring harness
— Female terminal opening is loose.
— Coupler (pin holder) damage
— Pin discoloration (blackness)
— Wiring harness/pin crimp is loose or disconnected.
01-03–81
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5. Verify that the engine speed is within the specification under each load condition.
• If the load condition is not as specified, inspect the following:
— A/C switch and related wiring harness
(See07-40-13 CLIMATE CONTROL UNIT INSPECTION [FULL-AUTO AIR CONDITIONER].)
(See07-40-16 CLIMATE CONTROL UNIT INSPECTION [MANUAL AIR CONDITIONER].)
— Fan switch and related wiring harness
(See07-40-13 CLIMATE CONTROL UNIT INSPECTION [FULL-AUTO AIR CONDITIONER].)
(See07-40-16 CLIMATE CONTROL UNIT INSPECTION [MANUAL AIR CONDITIONER].)
— PSP switch and related wiring harness
(See01-40-22 POWER STEERING PRESSURE (PSP) SWITCH INSPECTION[L3 WITH TC].)
Engine speed
Engine speed (rpm)
Load condition
P, N position D position
No load 650— 750 575— 675
E/L operating*1 650— 750 600— 700
P/S operating 650— 750 650— 750
A/C operating 650— 750 650— 750
*1
: When the following electrical loads are on: Headlights, rear defroster, cooling fan No.1, cooling fan No.2, and
the blower motor (2-step or more.)
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01-03–83
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01-03–84
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Note
• This inspection has to be performed after the Fuel Injector Operation Inspection.
Specification
8.0— 11.5 V (Ignition switch at ON)
Caution
• Connecting the wrong check connector terminal may possibly cause a malfunction. Carefully
connect the specified terminal only.
1. Short the check connector terminal F/P to body ground using a jumper wire.
2. Remove the fuel-filler cap.
3. Turn the ignition switch to the ON position.
4. Verify that the fuel pump operation sound is heard.
• If no operation sound is heard, proceed to the next step.
01-03–85
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Specification
8.0— 11.5 V (Ignition switch at on)
01-03–86
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
SYMPTOM TROUBLESHOOTING [L3 WITH TC]
Spark Test
1. Disconnect the fuel pump relay.
2. Verify that each ignition coil and connector is connected properly.
3. Inspect the ignition system in the following procedure.
Warning
• High voltage in the ignition system can cause strong electrical shock which can result in serious
injury. Avoid direct contact to the vehicle body during the following spark test.
01-03
STEP INSPECTION ACTION
1 • Disconnect the ignition coil from the spark Yes Go to the next step.
plugs. No Perform no-load racing at 4,000 rpm for 2 min, 2 times to
• Remove the spark plugs. burn off the carbon deposits.
• Verify that the spark plugs do not have Repeat Step 1.
carbon deposits.
• Are the spark plugs normal?
2 • Inspect the spark plugs for damage, wear, Yes Go to the next step.
and proper plug gap. No Replace spark plugs, then go to the next step.
• Are the spark plugs normal?
3 • Reconnect the spark plugs to the ignition Yes Ignition system is normal.
coil. No Some cylinders do not spark:
• Ground the spark plugs to the engine.
• Go to the next step.
• Is a strong blue spark visible at each cylinder
while cranking the engine? All cylinders do not spark:
• Go to Step 5.
4 • Inspect the following wiring harnesses for an Yes Inspect and replace the ignition coil.
open or short circuit: (See01-18-2 IGNITION COIL INSPECTION[L3 WITH TC].)
— Ignition coil No.1 terminal C—PCM No Repair or replace the malfunctioning part, then go to Step 1.
terminal 2BA
— Ignition coil No.2 terminal C—PCM
terminal 2AW
— Ignition coil No.3 terminal C—PCM
terminal 2AX
— Ignition coil No.4 terminal C—PCM
terminal 2AT
• Are the wiring harnesses normal?
5 • Measure the voltage at terminal A in each Yes Go to the next step.
ignition coils. No Inspect the power supply circuit of ignition coils.
• Is the voltage B+?
6 • Does the PCM connector or ignition coil Yes Repair or replace the connector, then go to Step 1.
connectors have poor connection? No Go to the next step.
7 • Are the following parts normal? Yes Inspect for an open or short circuit in the wiring harness and
— CKP sensor and crankshaft pulley connector of the CKP sensor.
No Repair or replace the malfunctioning part, then go to Step 1.
01-03–88
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Warning
• When the dynamometer or chassis roller is operating, there is a possibility that the operator may
come into contact with or be caught up in the rotating parts, leading to serious injuries or death.
When performing work while the dynamometer or chassis roller is operating, be careful not to
contact or be caught up in any of the rotating parts.
01-03
11. Drive vehicle at an engine speed to approx. 2000 rpm for 30 s or more.
12. Put a finger to the purge solenoid valve and verify that there is no vacuum applied during Step 2.
• If there is no vacuum, inspect the following:
— Wiring harness and connector (Main relay—purge solenoid valve—PCM terminal 2AB)
— Purge solenoid valve
— MAF, APP1, APP2, TP_REL and LOAD PIDs
• If there is vacuum, inspect the following:
— Vacuum hose (Purge solenoid valve—charcoal canister)
A/C Cut-off Control System Inspection
1. Start the engine.
2. Turn the A/C switch and fan switch on.
3. Verify that the A/C compressor magnetic clutch actuates.
• If it does not actuate, go to symptom troubleshooting “No.23 A/C does not work sufficiently“.
4. Fully open the throttle valve and verify that the A/C compressor magnetic clutch does not actuate for 2— 5 s.
• If it actuates, inspect as follows:
— A/C relay
— Open or short to ground circuit in the wiring harness and connectors (Ignition switch—A/C relay—PCM
terminal 1I)
— A/C related parts
— APP1, APP2 PIDs
Cooling Fan Control System Inspection
1. Connect the M-MDS to the DLC-2.
2. Start the engine and warm it up to normal operating temperature.
3. Perform the KOER self-test.
(See01-02-10 KOEO/KOER SELF TEST[L3 WITH TC].)
4. Verify that the DTC P0480 is not shown and the cooling fan operates during the KOER self-test.
• If DTC P0480 is shown, perform the DTC troubleshooting procedure.
(See01-02-152 DTC P0480[L3 WITH TC].)
• If the cooling fans do not operate, proceed to the following:
(1) Verify the clicking sound of the cooling fan relay when the ignition switch is turned from the off to the ON
position.
(2) If there is no the clicking sound, inspect the cooling fan relay for an open circuit between the ignition switch
and the cooling fan relay.
• If there is a clicking sound, go to the next step.
• Inspect the following parts in the indicated order in accordance with fan operation conditions.
Cooling fans do not operate
— Open circuit between the fan control module and the cooling fan relay
— Open circuit between fan control module and ground
— Poor connection of the fan control module connector
— Fan control module
(See01-12-14 FAN CONTROL MODULE INSPECTION[L3 WITH TC].)
Cooling fan motor No.1 does not operate
— Open or short to ground circuit between the fan control module and cooling fan motor No.1
— Poor connection of the fan control module connector or cooling fan motor No.1 connector
— Cooling fan motor No.1
(See01-12-14 FAN MOTOR INSPECTION[L3 WITH TC].)
— Fan control module
(See01-12-14 FAN CONTROL MODULE INSPECTION[L3 WITH TC].)
Cooling fan motor No.2 does not operate
— Open or short to ground circuit between the fan control module and the cooling fan motor No.2
— Poor connection of the fan control module connector or the cooling fan motor No.1 connector
— Cooling fan motor No.2
(See01-12-14 FAN MOTOR INSPECTION[L3 WITH TC].)
— Fan control module
(See01-12-14 FAN CONTROL MODULE INSPECTION[L3 WITH TC].)
01-03–89
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01-03–90
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Note
EVAP system test outline
• The EVAP system test, which can substituted for the run-drive cycle as an EVAP control system repair
confirmation method, can be done while operating the M-MDS in the KOEO (Key On Engine Off) condition
instead of actually driving the vehicle.
EVAP system test description
• The EVAP system test finds gas leaks in the system using the PCM to monitor changes in the air pump
load current of the EVAP system leak detection pump. This test starts after sending an on-demand test
signal from the M-MDS to the PCM. The PCM controls the air pump and change-over-valve operation and
also stores the load current of the air pump as follows:
i. The PCM turns the air pump on and retrieves the air pump load current value (LDP_MON PID) as a
reference current (LDP_REF PID).
ii. After retrieving the reference current value, the PCM commands the change-over-valve to open, then
captures the air pump load current value (LDP_MON PID) as the idle current (LDP_IDL PID). The
EVAP system will be pressurized from this phase.
01-03–91
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AIR-PUMP ON OFF
(LDP-REF) PASS
LOAD FAIL
CURRENT
(LDP-MON)
(LDP-IDL)
acxuuw00000321
ORIFICE
P
AIR-PUMP
AIR FILTER
AIR
acxuuw00000322
01-03–92
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Note
• To successfully perform this procedure, all PIDs must be within the following specifications before
proceeding to the next step.
• The PCM will cancel the EVAP system test if the B+ PID value falls lower than 11.0 V during the test. 01-03
Specification
PID PID Range
BARO 72.2 kPa {543 mmHg, 21.3 inHg} or more
FLI 15— 85%
IAT 5— 45 °C {41— 113 °F}
B+ 11.0 V or more
Note
• If the tester does not work correctly during the self-test, refer to the tester operators manual for a more
detailed self-test procedure.
01-03–93
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Note
• The COV is closed for 10 min unless any of the following actions are performed:
— The engine is started.
— The ignition switch is turned off.
6. Make sure the control valve on the 134-01049 is in the HOLD position and that the valve on the cylinder of
nitrogen gas is open.
7. Turn the control valve to the open position and let the system fill. You should note a drop in the gauge pressure
along with the flow meter being pegged at maximum flow for several minutes depending on how full or empty
the fuel tank is, and how long it takes to completely fill and pressurize the evaporative emissions system hoses.
8. If the gauge and the flow meter do not settle to a measurable level after 2— 3 min, then refer to the Mazda
Workshop Manual to verify that the cut or vent valve is properly closed.
9. Verify the pressure gauge and flow meter reading to determine if there is an evaporative emissions leak:
NO EVAPORATIVE LEAK:
• The flow meter registers “zero flow” and the pressure gauge returns to the pre-set pressure of 356 mm {14
in} of water (H2O).
EVAPORATIVE LEAK:
• The pressure does not return to the preset level of 356 mm {14 in} of water (H2O) when measuring the
flow. See “SETTING LEAK STANDARD FOR TESTING” (.020 to. 040 inch H2O) of the Evaporative
Emissions Tester operators manual (134-01067).
Note
• Turn the control valve to the HOLD position then disconnect the SST.
End Of Sie
01-03–94
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
MECHANICAL [L3 WITH TC]
01-10 MECHANICAL [L3 WITH TC]
MECHANICAL LOCATION INDEX CYLINDER HEAD GASKET
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-10–2 REPLACEMENT[L3 WITH TC] . . . . . . . 01-10–20
DRIVE BELT INSPECTION Camshaft Removal Note . . . . . . . . . . . . 01-10–22
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-10–3 Cylinder Head Removal Note . . . . . . . . 01-10–22
DRIVE BELT REMOVAL/INSTALLATION Cylinder Head Installation Note. . . . . . . 01-10–22
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-10–3 Camshaft Installation Note . . . . . . . . . . 01-10–23 01-10
DRIVE BELT AUTO TENSIONER FRONT OIL SEAL REPLACEMENT
INSPECTION[L3 WITH TC] . . . . . . . . . 01-10–4 [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-10–23
VALVE CLEARANCE Crankshaft Pulley Lock Bolt
INSPECTION/ADJUSTMENT Removal Note. . . . . . . . . . . . . . . . . . . 01-10–24
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-10–4 Front Oil Seal Removal Note. . . . . . . . . 01-10–25
Valve Clearance Front Oil Seal Installation Note . . . . . . . 01-10–25
Inspection . . . . . . . . . . . . . . . . . . . . . 01-10–4 Crankshaft Pulley Lock
Valve Clearance Bolt Installation Note . . . . . . . . . . . . . . 01-10–25
Adjustment . . . . . . . . . . . . . . . . . . . . . 01-10–5 REAR OIL SEAL REPLACEMENT
COMPRESSION INSPECTION [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-10–26
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-10–9 Rear Oil Seal Installation Note . . . . . . . 01-10–27
TIMING CHAIN VARIABLE VALVE TIMING ACTUATOR
REMOVAL/INSTALLATION INSPECTION[L3 WITH TC] . . . . . . . . . . 01-10–28
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-10–10 VARIABLE VALVE TIMING ACTUATOR
Cylinder Head Cover REMOVAL/INSTALLATION
Removal Note . . . . . . . . . . . . . . . . . . 01-10–12 [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-10–28
Crankshaft Pulley Lock Bolt OIL CONTROL VALVE (OCV)
Removal Note . . . . . . . . . . . . . . . . . . 01-10–12 REMOVAL/INSTALLATION
No.3 Engine Mount [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-10–29
Removal Note . . . . . . . . . . . . . . . . . . 01-10–12 OIL CONTROL VALVE (OCV)
Front Oil Seal Removal Note . . . . . . . . 01-10–14 INSPECTION[L3 WITH TC]. . . . . . . . . . 01-10–29
Chain Tensioner Removal Note . . . . . . 01-10–14 Coil Resistance Inspection . . . . . . . . . . 01-10–29
Oil Pump Driven Sprocket Spool Valve Operation Inspection . . . . . 01-10–29
Removal Note . . . . . . . . . . . . . . . . . . 01-10–15 ENGINE REMOVAL/INSTALLATION
Oil Pump Drive Sprocket
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-10–31
Installation Note . . . . . . . . . . . . . . . . 01-10–15
No.1 Engine Mount
Oil Pump Driven Sprocket
Removal Note . . . . . . . . . . . . . . . . . . . 01-10–33
Installation Note . . . . . . . . . . . . . . . . 01-10–16
No.3 Engine Mount Rubber, No.4
Timing Chain Installation Note . . . . . . . 01-10–16
Engine Mount Bracket
Front Oil Seal Installation Note . . . . . . 01-10–16
Removal Note . . . . . . . . . . . . . . . . . . . 01-10–33
Engine Front Cover
Engine Mount Installation Note . . . . . . . 01-10–33
Installation Note . . . . . . . . . . . . . . . . . 01-10–17
ENGINE DISASSEMBLY/ASSEMBLY
No.3 Engine Mount
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-10–35
Installation Note . . . . . . . . . . . . . . . . 01-10–17
ENGINE TUNE-UP[L3 WITH TC] . . . . . . . 01-10–35
Crankshaft Pulley Lock
Engine Tune-up Preparation . . . . . . . . . 01-10–35
Bolt Installation Note . . . . . . . . . . . . . 01-10–18
Ignition Timing Inspection . . . . . . . . . . . 01-10–36
Cylinder Head Cover
Idle Speed Inspection . . . . . . . . . . . . . . 01-10–36
Installation Note . . . . . . . . . . . . . . . . 01-10–19
Idle Mixture Inspection . . . . . . . . . . . . . 01-10–36
End of Toc
WM: ENGINE COMPLETE
8
1
7
6
4
acxuuw00000134
id011039801500
Note
• Drive belt deflection/tension inspection is not necessary because of the use of the drive belt auto
tensioner.
1. Verify that the drive belt auto tensioner indicator mark does not exceed the limit.
• If it exceeds the limit, replace the drive belt. 01-10
(See01-10-3 DRIVE BELT REMOVAL/
INSTALLATION[L3 WITH TC].)
End Of Sie
INDICATOR
MARK
NORMAL
MALFUNCTION
acxuuw00000135
acxuuw00000136
01-10–3
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acxuuw00000137
(4) Rotate the crankshaft clockwise 360° so that the No.4 cylinder is at TDC of the compression stroke.
(5) Measure the valve clearance of location B shown in the figure.
(6) If not within the specification, replace the tappet and adjust the valve clearance to the median value of the
standard.
10. Install the cylinder head cover. (See01-10-10 TIMING CHAIN REMOVAL/INSTALLATION[L3 WITH TC].)
11. Install the ventilation hose.
12. Connect the wiring harness.
13. Install the ignition coils. (See01-18-2 IGNITION COIL REMOVAL/INSTALLATION[L3 WITH TC].)
14. Install the high pressure fuel pump. (See01-14-16 HIGH PRESSURE FUEL PUMP REMOVAL/
INSTALLATION[L3 WITH TC].)
15. Install the charge air cooler. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
16. Install the splash shield (RH).
17. Connect the negative battery cable.
01-10–4
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UPPER
BLIND
PLUG
LOWER BLIND
PLUG
acxuuw00000157
303-507
acxuuw00000541
BOLT(M6 x 1.0)
3
acxuuw00000159
01-10–5
1871-1U-06B(01-10).fm 6 ページ 2006年3月15日 水曜日 午前10時39分
acxuuw00000160
acxuuw00000161
EXHAUST
CAMSHAFT
SPROCKET
acxuuw00000162
Note EX
• The camshaft caps are to be kept ordered No.1 No.2 No.3 No.4
for correct reassembly in their original
positions. Do not mix the caps. IN
22. Install the camshaft with No.1 cylinder cam aligned at TDC of the compression stroke.
01-10–6
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
MECHANICAL [L3 WITH TC]
23. Carefully apply adhesive agent (Loctite 518 or
962) to the area indicated in the figure so that it
does not leak into the sliding part.
Thickness SEALANT
01-10
acxuuw00000166
Caution
• Do not tighten the camshaft sprocket
installation bolt at this stage. Verify the
valve timing before performing the bolt
tightening.
EXHAUST
CAMSHAFT
SPROCKET
acxuuw00000162
acxuuw00000167
Tightening torque
69— 75 N·m {7.1— 7.6 kgf·m, 51— 55 ft·lbf}
Tightening torque
8.0— 11.5 N·m {82— 117 kgf·cm, 71— 101
in·lbf}
BLIND
PLUG
acxuuw00000168
Tightening torque
18— 22 N·m {1.9— 2.2 kgf·m, 14— 16 ft·lbf}
BLIND
PLUG
acxuuw00000169
01-10–8
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Warning
• Hot engines can cause severe burns. Be careful not to burn yourself during removal/installation of
each component.
• Fuel vapor is hazardous. It can very easily ignite, causing death, serious injury, or damage. Always
keep sparks and flames away from fuel.
1. Verify that the battery is completely charged. (See01-17-2 BATTERY INSPECTION[L3 WITH TC].)
2. Warm up the engine.
Warning
• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can easily ignite
and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent
this, always perform the Fuel Line Safety Procedure. (See01-14-4 BEFORE REPAIR
PROCEDURE[L3 WITH TC].)
Compression
Standard: 1,280 kPa {13.1 kgf/cm2, 185.65
psi} [250rpm]
Minimum: 896 kPa {9.14 kgf/cm2, 129.96 psi}
[250rpm]
Maximum difference between cylinders: acxuuw00000151
01-10–9
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Note
• Position and secure the P/S oil pump out of the way with a rope or wire.
01-10–10
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
MECHANICAL [L3 WITH TC]
74.5—104.9
SST {7.6—10.6,
55.0—77.3 }
6
8.0—9.5 N·m {82—96
kgf·cm, 71—84 in·lbf}
74.5—104.9 01-10
{7.6—10.6, 1
55.0—77.3 } SEALANT
7 8.0—11.5 N·m
40—55 {82—117 kgf·cm,
{4.1—5.6, 71—101 in·lbf}
30—40}
74.5—104.9
{7.6—10.6, 13
55.0—77.3 }
5
R
R
20—30 OIL
{2.1—3.0,
SST
15—22} 8
SEALANT
3
4
SEALANT
SEALANT
17—23
2 R SST {1.8—2.3, 13—16}
96—104 {9.8—10.6, 9
70.9—76.7}
+87°—93°
A
12 R
A : 8.0—11.5 N·m
{82—117 kgf·cm, SST
71—101 in·lbf}
10
16
19 14
15 20—30
18 {2.1—3.0,
A
15—22}
11 A
8.0—11.5 N·m
{82—117 kgf·cm, 17
71—101 in·lbf} N·m {kgf·m, ft·lbf}
acxuuw00002555
2
1
6
10 11 7
acxuuw00000219
acxuuw00000678
205-126
acxuuw00002077
acxuuw00000222
01-10–12
1871-1U-06B(01-10).fm 13 ページ 2006年3月15日 水曜日 午前10時39分
Caution
• Refer to the SST instruction manual for MAIN FRAME
the basic handing procedure.
REAR SHAFT
01-10
SIDE BAR
FRONT SHAFT
acxuuw00000224
acxuuw00000225
01-10–13
1871-1U-06B(01-10).fm 14 ページ 2006年3月15日 水曜日 午前10時39分
acxuuw00000226
acxuuw00000227
PLUNGER
acxuuw00000228
RATCHET
acxuuw00000229
01-10–14
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
MECHANICAL [L3 WITH TC]
3. Release the ratchet with the plunger still pressed
down.
RATCHET
01-10
acxuuw00000230
WIRE INSERTION
HOLE
acxuuw00000231
ENGINE FRONT
CRANKSHAFT SPROCKET
acxuuw00000233
Tightening torque
20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}
CRANKSHAFT OIL PUMP DRIVEN
PULLEY SPROCKET
acxuuw00002573
acxuuw00000234
49 H010 401
acxuuw00000235
49 H010 401
FRONT OIL SEAL
acxuuw00000236
Caution
• Install the engine front cover within 10 min of applying the silicone sealant.
• Silicone sealant is not needed in area C
shown in the figure. B
01-10
Thickness
A: 2.2— 3.2 mm {0.087— 0.12 in}
B: 1.5— 2.5 mm {0.06— 0.098 in}
C B
acxuuw00000237
9 12
13
16
15 14
acxuuw00000238
Tightening torque
7.0— 13 N·m {72— 132 kgf·cm, 62— 115
in·lbf}
No.3 ENGINE
Note MOUNT
• If the No.3 engine joint bracket and the BRACKET
engine are removed, retighten the No.3 STUD BOLT
engine mount stud bolt
acxuuw00000239
01-10–17
1871-1U-06B(01-10).fm 18 ページ 2006年3月15日 水曜日 午前10時39分
3 5
1
FRONT
acxuuw00000241
3. Tighten the bolts and nuts in the order shown in
the figure. 4
Tightening torque 1
74.5— 104.9 N·m {7.6— 10.6 kgf·m, 55.0—
77.3 ft·lbf}
5 2
FRONT
3
acxuuw00000242
acxuuw00000234
3. To position the crankshaft pulley, temporarily
tighten it and, using a suitable bolt (M6 X 1.0
length 25— 35 mm {0.99— 1.3 in}), fix the
crankshaft pulley to the engine front cover.
BOLT
acxuuw00000243
4. Install theSSTs to the crankshaft pulley, lock the
crankshaft against rotation, and tighten the
crankshaft pulley lock bolt using the following two 205-07202
steps.
Tightening procedure
(1) 96— 104 N·m {9.8— 10.6 kgf·m, 70.9—
76.7 ft·lbf}
(2) 87°— 93°
205-126
acxuuw00002077
01-10–18
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
MECHANICAL [L3 WITH TC]
5. Remove the bolt (M6 X 1.0 length 25— 35 mm {0.99— 1.3 in}) installed to the crankshaft pulley.
6. Remove the SST from the camshaft.
7. Remove the SST installed in the cylinder block lower blind plug hole.
8. Rotate the crankshaft clockwise two turns and inspect the valve timing.
• If not aligned, repeat from Step 1.
9. Install the cylinder block lower blind plug.
BLIND
PLUG
acxuuw00000244
SEALANT
acxuuw00000245
Thickness
5.0 mm {0.20 in}
SEALANT
SEALANT
acxuuw00000246
9
5 4 8
acxuuw00000247
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing death, serious injury, or damage. Always
keep sparks and flames away from fuel.
• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can easily ignite
and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent
this, always perform the Fuel Line Safety Procedure. (See01-14-4 BEFORE REPAIR
PROCEDURE[L3 WITH TC].)
1. Remove the timing chain. (See01-10-10 TIMING CHAIN REMOVAL/INSTALLATION[L3 WITH TC].)
2. Remove the generator. (See 01-17-4 GENERATOR REMOVAL/INSTALLATION[L3 WITH TC].)
Note
• Place the generator out of the way with the wiring harnesses connected.
3. Remove the exhaust manifold. (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
4. Remove the intake manifold. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
5. Disconnect the heater hose and radiator hose.
6. Disconnect the wiring harness.
7. To firmly support the engine, first set the engine ENGINE, TRANSAXLE
jack and attachment to the oil pan.
8. Remove in the order indicated in the figure.
9. Install in the reverse order of removal.
10. Bleed the air from the cooling system. (See01-12- ATTACHMENT
5 ENGINE COOLANT REPLACEMENT[L3 WITH
TC].)
11. Inspect the compression pressure. (See01-10-9
COMPRESSION INSPECTION[L3 WITH TC].)
ENGINE JACK
acxuuw00000249
01-10–20
1871-1U-06B(01-10).fm 21 ページ 2006年3月15日 水曜日 午前10時39分
SEALANT
01-10
1
OIL 2
R 4
acxuuw00000250
01-10–21
1871-1U-06B(01-10).fm 22 ページ 2006年3月15日 水曜日 午前10時39分
Note
• The camshaft caps are to be kept ordered for correct reassembly in their original positions.
EX
IN
2 4 6 5 3 1
acxuuw00000251
4 8 9 5 1
acxuuw00000252
acxuuw00000253
Tightening procedure 8 4 1 5 9
1. 3.0— 11 N·m {31— 112 kgf·cm, 27— 97
in·lbf}
2. 13— 17 N·m {133— 173 kgf·cm, 116— 150
in·lbf}
3. 43— 47 N·m {4.4— 4.7 kgf·m, 32— 34 ft·lbf}
4. 88°— 92°
5. 88°— 92°
7 3 2 6 10
acxuuw00000254
01-10–22
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
MECHANICAL [L3 WITH TC]
Camshaft Installation Note
1. Install the camshaft with No.3 cylinder cam aligned at TDC of compression stroke.
2. Carefully apply adhesive agent (Loctite 518 or
962) to the area indicated in the figure so that it
does not leak into the sliding part.
Thickness SEALANT
acxuuw00000255
acxuuw00002078
2 R
R
SST
1 3
R SST
OIL
acxuuw00002584
acxuuw00001897
205-126
acxuuw00002079
01-10–24
1871-1U-06B(01-10).fm 25 ページ 2006年3月15日 水曜日 午前10時39分
01-10
RAG
acxuuw00000199
49 H010 401
acxuuw00000200
49 H010 401
FRONT OIL SEAL
acxuuw00000201
acxuuw00000202
01-10–25
1871-1U-06B(01-10).fm 26 ページ 2006年3月15日 水曜日 午前10時39分
BOLT
acxuuw00000203
Tightening procedure
(1) 96— 104 N·m {9.8— 10.6 kgf·m, 70.9—
76.7 ft·lbf}
(2) 87°— 93°
Tightening torque
18— 22 N·m {1.9— 2.2 kgf·m, 14— 16 ft·lbf}
End Of Sie
WM: REAR OIL SEAL
BLIND
PLUG
acxuuw00000204
1
8.0—11.5
OIL
{82—117, R SST
71—101} 2
N·m {kgf·cm, in·lbf}
acxuuw00000146
01-10–26
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
MECHANICAL [L3 WITH TC]
Rear Oil Seal Installation Note
1. Apply silicone sealant to the areas shown in the
figure.
Caution
• Install the rear oil seal within 10 min of
applying the silicone sealant.
01-10
Thickness
4.0— 6.0 mm {0.16— 0.23 in}
SEALANT
acxuuw00002559
4. From the back side of the rear oil seal, verify that BACK SIDE OF REAR OIL SEAL
there is no damage or separation in the lip area of
the rear oil seal. LIP AREA
acxuuw00002560
5. Install the rear oil seal to the engine as shown in
the figure.
acxuuw00002561
2 4
acxuuw00000149
Caution
• Due to the precision interior construction of the variable valve timing actuator, it cannot be
disassembled.
1. Disconnect the negative battery cable.
2. Remove the charge air cooler. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
3. Remove the ignition coils. (See01-18-2 IGNITION COIL REMOVAL/INSTALLATION[L3 WITH TC].)
4. Remove the spark plugs. (See01-18-3 SPARK PLUG REMOVAL/INSTALLATION[L3 WITH TC].)
5. Disconnect the wiring harness.
6. Remove the ventilation hose.
7. Remove cylinder head cover. (See01-10-10 TIMING CHAIN REMOVAL/INSTALLATION[L3 WITH TC].)
8. Verify that the groove of the rotor and notch of the
cover on the variable valve timing actuator are
aligned and fitted.
• If they are not aligned, rotate the crankshaft in
the direction of engine rotation two times and NOTCH
verify that they are aligned.
— If they will not align, replace the variable
valve timing actuator.
• If under any condition, the variable valve
timing actuator always makes a hitting noise
directly after the camshaft exceeds maximum
lift while rotating the crankshaft two times in
the direction of engine rotation, replace the acxuuw00000143
variable valve timing actuator as it has not
been fixed.
9. Install the cylinder head cover. (See01-10-10 TIMING CHAIN REMOVAL/INSTALLATION[L3 WITH TC].)
10. Install the ventilation hose.
11. Connect the wiring harness.
12. Install the spark plugs. (See01-18-3 SPARK PLUG REMOVAL/INSTALLATION[L3 WITH TC].)
13. Install the ignition coils. (See01-18-2 IGNITION COIL REMOVAL/INSTALLATION[L3 WITH TC].)
14. Install the charge air cooler. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
15. Connect the negative battery cable.
End Of Sie
VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION[L3 WITH TC]
id011039801100
Caution
• Remove the variable valve timing actuator and camshaft sprocket as a single unit.
Note
• The variable valve timing actuator and camshaft sprocket cannot be disassembled.
1. Referring to the valve clearance adjustment procedure, remove the variable valve timing actuator and the
camshaft on the intake air side as a single unit. (See01-10-4 VALVE CLEARANCE INSPECTION/
ADJUSTMENT[L3 WITH TC].)
2. Remove the variable valve timing actuator.
(1) Place alignment marks on the camshaft and variable valve timing actuator as shown in the figure so that the
variable valve timing actuator is re-assembled in its original position.
(2) Fix the camshaft in a vise.
(3) Loosen the variable valve timing actuator
installation bolt.
End Of Sie
MARK
acxuuw00000144
01-10–28
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
MECHANICAL [L3 WITH TC]
01-10-28 MECHANICAL [L3 WITH TC]
Caution
• If replacing with a new variable valve R 01–10
timing actuator, place alignment marks in
the same positions as those prior to the
replacement.
acxuuw00000145
(3) Tighten the variable valve timing actuator
installation bolt.
Tightening torque
69— 75 N·m {7.1— 7.6 kgf·m, 51— 55 ft·lbf}
5. Referring to the valve clearance adjustment procedure, install the variable valve timing actuator and camshaft
on the intake air side as a single unit. (See01-10-4 VALVE CLEARANCE INSPECTION/ADJUSTMENT[L3
WITH TC].)
End Of Sie
01-10-28–1
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
MECHANICAL [L3 WITH TC]
01-10-28–2
1871-1U-06B(01-10).fm 29 ページ 2006年3月15日 水曜日 午前10時39分
Tightening torque
8.0— 11.5 N·m {82— 117 kgf·cm, 71— 101
in·lbf}
End Of Sie
acxuuw00000138
acxuuw00000139
SPOOL VALVE
(MAXIMUM VALVE TIMING RETARD POSITION
acxuuw00000140
01-10–29
1871-1U-06B(01-10).fm 30 ページ 2006年3月15日 水曜日 午前10時39分
acxuuw00000139
Note
• When applying battery positive voltage
between the OCV terminals, the connection
VALVE TIMING VALVE TIMING
can be either of the following:
ADVANCE RETARD
— Positive battery cable to terminal A,
Negative battery cable to terminal B
— Positive battery cable to terminal B,
Negative battery cable to terminal A
SPOOL VALVE
(MAXIMUM VALVE TIMING ADVANCE POSITION)
acxuuw00000142
7. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve timing retard
position.
• If not as specified, replace the OCV. (See01-10-29 OIL CONTROL VALVE (OCV) REMOVAL/
INSTALLATION[L3 WITH TC].)
8. Connect the OCV connector.
9. Connect the negative battery cable.
End Of Sie
WM: ENGINE COMPLETE
01-10–30
1871-1U-06B(01-10).fm 31 ページ 2006年3月15日 水曜日 午前10時39分
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing death, serious injury, or damage. Always
keep sparks and flames away from fuel.'
• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can easily ignite
and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent
this, always perform the Fuel Line Safety Procedure. (See01-14-4 BEFORE REPAIR 01-10
PROCEDURE[L3 WITH TC].)
Note
• Position and secure the A/C compressor out of the way with rope.
01-10–31
1871-1U-06B(01-10).fm 32 ページ 2006年3月15日 水曜日 午前10時39分
66.6—93.1 {6.8—9.4,
2 50—68}
66.6—93.1
{6.8—9.4,
50—68}
74.5—104.9
{7.6—10.6,
55.0—77.3}
1
B
A
B
A
85.3—116.6
{8.7—11.8,
63.0—85.9}
acxuuw00000185
01-10–32
1871-1U-06B(01-10).fm 33 ページ 2006年3月15日 水曜日 午前10時39分
FRONT
01-10
acxuuw00000186
No.1 ENGINE
MOUNT RUBBER
acxuuw00000187
No.3 Engine Mount Rubber, No.4 Engine Mount Bracket Removal Note
1. Secure the engine and transaxle using an engine ENGINE, TRANSAXLE
jack and attachment.
ATTACHMENT
ENGINE JACK
acxuuw00000188
Tightening torque
7.0— 13 N·m {72— 132 kgf·cm, 62— 115
in·lbf}
No.3 ENGINE
MOUNT
BRACKET
STUD BOLT
acxuuw00000189
01-10–33
1871-1U-06B(01-10).fm 34 ページ 2006年3月15日 水曜日 午前10時39分
Tightening torque
93.1— 116.6 N·m {9.5— 11.8 kgf·m, 68.7—
FRONT
85.9 ft·lbf}
2
1
acxuuw00000190
ATTACHMENT
ENGINE JACK
acxuuw00000188
FRONT
acxuuw00000191
FRONT
acxuuw00000191
2 FRONT
1
acxuuw00000192
01-10–34
1871-1U-06B(01-10).fm 35 ページ 2006年3月15日 水曜日 午前10時39分
Tightening torque
85.3— 116.6 N·m {8.7— 11.8 kgf·m, 63.0— FRONT
85.9 ft·lbf}
End Of Sie
acxuuw00000194
Note
• If the accelerator pedal is depressed continuously for a specified time, the engine speed may decrease to
the idle speed. This is due to the fuel cut control operation, which prevents overheating, and it does not
indicate a malfunction.
DLC-2
acxuuw00000150
01-10–35
1871-1U-06B(01-10).fm 36 ページ 2006年3月15日 水曜日 午前10時39分
Note
• The ignition timing cannot be adjusted.
• The M-MDS is required to verify the ignition timing.
1. Verify the ignition timing (M-MDS: SPARKADV) using the PID/data monitor function of the M-MDS.
Ignition timing
Approx. BTDC 10°
2. Verify that ignition timing advances when the engine speed increases gradually.
• If there is malfunction, refer to “ENGINE SYMPTOM TROUBLESHOOTING”. (See01-03-5 ENGINE
SYMPTOM TROUBLESHOOTING[L3 WITH TC].)
Note
• Idle speed is not adjustable.
• Idle speed verification requires M-MDS.
1. Verify that the idle speed (M-MDS: RPM PID) is within the specification using M-MDS.
• If there is malfunction, refer to “ENGINE SYMPTOM TROUBLESHOOTING”. (See01-03-5 ENGINE
SYMPTOM TROUBLESHOOTING[L3 WITH TC].)
*1 : When the following electrical loads are on: Headlights, rear defroster, cooling fan No.1, cooling fan No.2, and
the blower motor (2-step or more.)
Idle mixture
HC concentration: Within the regulation
CO concentration: Within the regulation
End Of Sie
01-10–36
1871-1U-06B(01-11).fm 1 ページ 2006年3月15日 水曜日 午前10時42分
End of Toc
LUBRICATION SYSTEM LOCATION INDEX[L3 WITH TC]
WM: LUBRICATION SYSTEM
id011139800100
2
7 6
WASHER
acxuuw00001987
End Of Sie
WM: OIL PRESSURE
01-11–1
1871-1U-06B(01-11).fm 2 ページ 2006年3月15日 水曜日 午前10時42分
Warning
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands.
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.
Caution
• Make sure that there is no sealant between 1.0— 2.0 mm {0.04— 0.07 in} from the end of the oil
pressure switch to prevent a possible operation malfunction.
Tightening torque
12— 18 N·m {1.3— 1.8 kgf·m, 9— 13 ft·lbf}
01-11–2
1871-1U-06B(01-11).fm 3 ページ 2006年3月15日 水曜日 午前10時42分
acxuuw00002001
acxuuw00002002
acxuuw00002003
01-11–3
1871-1U-06B(01-11).fm 4 ページ 2006年3月15日 水曜日 午前10時42分
Warning
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands.
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.
Caution
• If engine oil is spilled on the exhaust system, wipe it off completely. If you fail to wipe the spilled
engine oil, it will produce fumes because of the heat.
Note
• The amount of residual oil in the engine can SCREW
vary according to factors such as the
acxuuw00001998
replacement method and oil temperature.
Verify the oil level after engine oil
replacement.
7. Refill with the following type and amount of the engine oil.
(ILSAC)
(ILSAC)
API SL or ILSAC
Engine oil viscosity 5W-30
id011139800700
Warning
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands. 01-11
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.
Caution
• If engine oil is spilled on the exhaust system, wipe it off completely. If you fail to wipe the spilled
engine oil, it will produce fumes because of the heat.
• To avoid damage to the oil filter, use only specified oil filter.
Note
• Oil could be easily drained when the air is in
the filter. OIL FILTER COVER
OIL FILTER DRAIN PLUG
5. Loosen the oil filter cover for another 1 turn.
acxuuw00002007
01-11–5
1871-1U-06B(01-11).fm 6 ページ 2006年3月15日 水曜日 午前10時42分
Warning
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands.
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.
1 Water hose
34—40 {3.5—4.0, 25.1—29.4}
2 Oil cooler
End Of Sie
R 2 1
WM: OIL PAN
1
OIL
OIL FILTER
ADAPTER
acxuuw00002009
Warning
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands.
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.
1. Complete the “BEFORE REPAIR PROCEDURE”. (See 01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH
TC].)
2. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].)
3. Remove the under cover.
4. Remove the splash shield (RH).
5. Drain the engine oil. (See 01-11-4 ENGINE OIL REPLACEMENT[L3 WITH TC].)
6. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT[L3 WITH TC].)
7. Remove the charge air cooler, air cleaner and fresh air duct component, and air hose. (See 01-13-5 INTAKE
AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
8. Disconnect the quick release connector on the high pressure fuel pump. (See 01-14-19 QUICK RELEASE
CONNECTOR REMOVAL/INSTALLATION[L3 WITH TC].)
9. Remove the high pressure fuel pump. (See 01-14-16 HIGH PRESSURE FUEL PUMP REMOVAL/
INSTALLATION[L3 WITH TC].)
01-11–6
1871-1U-06B(01-11).fm 7 ページ 2006年3月15日 水曜日 午前10時42分
37—52 {3.8—5.3,
28—38}
8.0—11.5 N·m
{82—117 kgf·cm,
71—101 in·lbf}
A
SEALANT 2 R
3
A
acxuuw00001992
01-11–7
1871-1U-06B(01-11).fm 8 ページ 2006年3月15日 水曜日 午前10時42分
Caution
• Apply the silicon sealant in a single, unbroken line around the whole perimeter.
• Using bolts with the old seal adhering could cause cracks in the housing.
OLD SEALANT
acxuuw00001993
acxuuw00001994
Thickness 2.2—3.2 mm
2.2— 3.2 mm {0.087— 0.126 in} {0.087—0.126 in}
acxuuw00001995
11
12 7 3 2 6
acxuuw00001996
01-11–8
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
LUBRICATION [L3 WITH TC]
6. Tighten the oil pan-transaxle installation bolts.
Tightening torque
37— 52 N·m {3.8— 5.3 kgf·m, 28— 38 ft·lbf}
End Of Sie
WM: OIL PUMP
01-11
Warning
• Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
• A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands.
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.
1. Complete the “BEFORE REPAIR PROCEDURE”. (See 01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH
TC].)
2. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].)
3. Remove the under cover.
4. Remove the splash shield (RH).
5. Drain the engine oil. (See 01-11-4 ENGINE OIL REPLACEMENT[L3 WITH TC].)
6. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT[L3 WITH TC].)
7. Remove the charge air cooler, air cleaner and fresh air duct component, and air hose. (See 01-13-5 INTAKE
AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
8. Disconnect the quick release connector on the high pressure fuel pump. (See 01-14-19 QUICK RELEASE
CONNECTOR REMOVAL/INSTALLATION[L3 WITH TC].)
9. Remove the high pressure fuel pump. (See 01-14-16 HIGH PRESSURE FUEL PUMP REMOVAL/
INSTALLATION[L3 WITH TC].)
10. Remove the ignition coils. (See 01-18-2 IGNITION COIL REMOVAL/INSTALLATION[L3 WITH TC].)
11. Loosen the water pump pulley bolts before removing the drive belt.
12. Remove the drive belt. (See 01-10-3 DRIVE BELT REMOVAL/INSTALLATION[L3 WITH TC].)
13. Remove the P/S oil pump with hose and pipe still connected. Position the P/S oil pump out of the way. (See 06-
14-21 POWER STEERING OIL PUMP REMOVAL/INSTALLATION.)
14. Remove the crankshaft position (CKP) sensor. (See 01-40-42 CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION[L3 WITH TC].)
15. Remove the engine front cover. (See 01-10-10 TIMING CHAIN REMOVAL/INSTALLATION[L3 WITH TC].)
16. Remove the oil pan. (See 01-11-6 OIL PAN REMOVAL/INSTALLATION[L3 WITH TC].)
17. Remove in the order indicated in the table.
18. Install in the reverse order of removal.
19. Refill with the specified type and amount of the engine oil. (See 01-11-4 ENGINE OIL REPLACEMENT[L3
WITH TC].)
20. Refill the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT[L3 WITH TC].)
21. Start the engine and confirm that there is no oil leakage.
• If there is oil leakage, repair or replace the applicable part.
22. Inspect the oil level. (See 01-11-3 ENGINE OIL LEVEL INSPECTION[L3 WITH TC].)
23. Inspect for engine coolant leakage. (See 01-12-6 ENGINE COOLANT LEAKAGE INSPECTION[L3 WITH TC].)
24. Inspect for the ignition timing and idle speed. (See 01-10-35 ENGINE TUNE-UP[L3 WITH TC].)
25. Inspect the oil pressure. (See 01-11-2 OIL PRESSURE INSPECTION[L3 WITH TC].)
01-11–9
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
LUBRICATION [L3 WITH TC]
2
8.0—11.5
{82—117,
71—101}
4
3
B
5
6
R
OIL
8.0—11.5
{82—117,
1
71—101}
Tightening torque
20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf} CRANKSHAFT OIL PUMP
PULLEY SPROCKET
acxuuw00002575
acxuuw00002006
End of Toc
WM: COOLING SYSTEM
01-12–1
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
COOLING SYSTEM [L3 WITH TC]
COOLING SYSTEM LOCATION INDEX[L3 WITH TC]
id011239800100
2 9
2 7
1
8
5
3
4
acxuuw00002010
.
End Of Sie
COOLING SYSTEM SERVICE WARNINGS[L3 WITH TC]
id011239800200
Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
• Depending on the vehicle, the cooling fan may operate suddenly even when the ignition switch is
turned off. Therefore, keep hands and tools away from the cooling fan even if the cooling fan is
not operating to prevent injury to personnel or damage to the cooling fan. Always disconnect the
negative battery cable when servicing the cooling fan or parts near the cooling fan.
Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while 01-12
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
Note
• If the “FL22” mark is shown on or near the cooling system cap, use FL22 type engine coolant.
• FL22 type engine coolant is shipped as a
diluted solution (55% coolant, 45% water).
Use the solution as is when replacing
coolant.
acxuuw00002056
acxuuw00002057
01-12–3
1871-1U-06B(01-12).fm 4 ページ 2006年3月15日 水曜日 午前10時43分
Caution
• Use engine coolant at a concentration that meets the environmental conditions in which the
vehicle is driven, otherwise engine damage could occur.
• The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to
prevent corrosion and freezing.
• Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could
damage the cooling system.
• Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut
down on the coolant’s effectiveness.
• Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.
Note
• If the “FL22” mark is shown on or near the cooling system cap, use FL22 type engine coolant.
• FL22 type engine coolant is shipped as a
diluted solution (55% coolant, 45% water).
Use the solution as is when replacing
coolant.
acxuuw00002058
1.08
1.07 55%
1.06
45%
1.05
35%
1.04
1.03
1.02
1.01
1.00
0 5 10 15 20 25 30 35 40 45 50
{32} {41} {50} {59} {68} {77} {86} {95} {104} {113} {122}
01-12–4
1871-1U-06B(01-12).fm 5 ページ 2006年3月15日 水曜日 午前10時43分
Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while 01-12
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
Caution
• Use engine coolant at a concentration that meets the environmental conditions in which the
vehicle is driven, otherwise engine damage could occur.
• The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to
prevent corrosion and freezing.
• Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could
damage the cooling system.
• Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut
down on the coolant's effectiveness.
• Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.
Note
• If the “FL22” mark is shown on or near the cooling system cap, use FL22 type engine coolant.
• FL22 type engine coolant is shipped as a
diluted solution (55% coolant, 45% water).
Use the solution as is when replacing
coolant.
acxuuw00002061
Tightening torque
1.5— 2.4 N·m {15— 25 kgf·cm, 13— 21 in·lbf}
6. Referring to the following chart, select the correct RADIATOR DRAIN PLUG
volume percentage of the water and engine
acxuuw00002062
coolant.
Antifreeze solution mixture percentage (Except FL22 type engine coolant)
Volume percentage (%)
Engine coolant protection Gravity at 20 °C {68 °F}
Water Coolant
Above -16 °C {3 °F} 65 35 1.057
Above -26 °C {-15 °F} 55 45 1.072
Above -40 °C {-40 °F} 45 55 1.086
01-12–5
1871-1U-06B(01-12).fm 6 ページ 2006年3月15日 水曜日 午前10時43分
Caution
• If the water temperature gauge rises too high, stop the engine and decrease the engine coolant
temperature to prevent overheating. Then, verify the malfunctioning part and repair or replace it.
Note
• If the accelerator pedal is depressed continuously for a specified time, the engine speed may decrease to
the idle speed. This is due to the fuel cut control operation, which prevents overheating, and it does not
indicate a malfunction.
Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
1. Inspect the engine coolant level. (See 01-12-3 ENGINE COOLANT LEVEL INSPECTION[L3 WITH TC].)
2. Remove the cooling system cap.
3. Install the SST and a radiator cap tester to the
radiator filler neck.
4. Apply pressure using the radiator cap tester.
49 9200 145
Caution
• Applying more than 142.2 kPa {1.45 kgf/
cm2, 20.6 psi} can damage the hoses,
fittings, and other components, and
cause leakage.
Pressure
142.2 kPa {1.45 kgf/cm2, 20.6 psi} [1 min] acxuuw00002060
5. When pressurizing the cooling system, verify that the pressure is maintained.
• If the gauge needle drops, it may indicate water leakage. Repair or replace the applicable part.
End Of Sie
WM: COOLING FAN MOTOR
01-12–6
1871-1U-06B(01-12).fm 7 ページ 2006年3月15日 水曜日 午前10時43分
Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
01-12
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
1. Clean the cooling system cap and the sealed part.
2. Inspect the cooling system cap for cracks or everted seal.
• If there is any malfunction, replace the cooling system cap.
3. Attach the cooling system cap to the SST and a
radiator cap tester.
49 9200 145
4. Hold the cooling system cap downward and apply
pressure gradually. Verify that the pressure is held
stable for 10 s.
• If the pressure is not held stable, replace the
cooling system cap.
acxuuw00002066
01-12–7
1871-1U-06B(01-12).fm 8 ページ 2006年3月15日 水曜日 午前10時43分
acxuuw00002067
Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
01-12–8
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
ON-BOARD DIAGNOSTIC [L3 WITH TC]
Simulation Function Procedure
1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (notebook PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Module”. DLC-2 01-02
4. Select “PCM”.
• When using the PDS (pocket PC)
1. Select “Module Tests”.
2. Select “PCM”.
3. Select “DataLogger”.
acxuuw00001891
3. Select the simulation items from the PID table.
4. Perform the simulation function, inspect the
operations for each parts.
• If there is no operation sound from the relay, motor, and solenoid after the simulation function inspection is
performed, it is possible that there is an open or short circuit in the wiring harness, relay, motor or solenoid,
or sticking and operation malfunction.
End Of Sie
DIAGNOSTIC MONITORING TEST RESULTS[L3 WITH TC]
id010239801400
• The purpose of this test mode is to confirm the result of the OBD-II monitor diagnostic test results. The result
values stored when a particular monitor is completed are displayed. If the monitor is not completed, the initial
value is displayed.
TEST ID Description Related system
10: 01: 80 HO2S (Front) lean-to-rich response time (calculated)
10: 02: 03 Low HO2S (Rear) voltage for switch time calculation (constant)
HO2S
10: 02: 04 High HO2S (Rear) voltage for switch time calculation (constant)
10: 02: 05 HO2S (Rear) rich-to-lean response time (calculated)
10: 21: 80 Front and HO2S (Rear) switching time ratio Catalyst
10: 31: 83 EGR pressure variation EGR
10: 3A: 80 EVAP system leak detection pump gross leak check
10: 3B: 80 EVAP system leak detection pump small leak check
EVAP
10: 3C: 80*1 EVAP system leak detection pump very small leak check
10: 3D: 80 Purge flow monitor
10: A2: 0B EWMA misfire counts for last 10 driving cycles
10: A2: 0C Misfire counts for last/current driving cycles
10: A3: 0B EWMA misfire counts for last 10 driving cycles
10: A3: 0C Misfire counts for last/current driving cycles
Misfire
10: A4: 0B EWMA misfire counts for last 10 driving cycles
10: A4: 0C Misfire counts for last/current driving cycles
10: A5: 0B EWMA misfire counts for last 10 driving cycles
10: A5: 0C Misfire counts for last/current driving cycles
10: E1: 80 Heat radiation ratio Engine cooling
10: E1: 81 Misfire counts for last/current driving cycles system
End Of Sie
01-02–9
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
ON-BOARD DIAGNOSTIC [L3 WITH TC]
AFTER REPAIR PROCEDURE[L3 WITH TC]
id010239801100
1. Connect the M-MDS to the DLC-2.
2. Cycle the ignition switch from the off to the ON
position.
3. Any retrieved DTCs.
4. Clear all diagnostic data using the M-MDS.
End Of Sie
DLC-2
acxuuw00001892
Note
• Perform a KOER self test with the engine idling after the engine speed increases to 2,000 rpm.
1. Perform the necessary vehicle preparation and visual inspection.
2. Connect the M-MDS to the vehicle DLC-2 16-pin connector located in the driver compartment.
3. Retrieve the KOEO/KOER DTCs using the M-MDS.
End Of Sie
OBD-II DRIVE MODE[L3 WITH TC]
id010239801300
• Using the OBD-II drive mode, the monitoring item requested by OBD-II regulations can be easily diagnosed.
• Performing the Drive Mode inspects the OBD-II system for proper operation and must be performed to ensure
that no additional DTCs are present.
• The OBD-II drive mode is divided into the specific drive mode and single drive mode.
• For the specific drive mode, specified drive modes have been set for each individual monitoring item requested
by OBD-II regulations, and they can be diagnosed individually. For the single drive mode, the entire monitoring
item requested by OBD-II regulations can be diagnosed.
• The following modes are in the specific drive mode. The applicable system is diagnosed by driving in the
following drive modes.
— PCM Adaptive Memory Produce Drive Mode
— EGR System Repair Verification Drive Mode
— HO2S heater, HO2S, and TWC Repair Verification Drive Mode
— EVAP System Repair Verification Drive Mode
• The following systems are diagnosed with the single drive mode.
— EGR system
— Oxygen sensor (HO2S)
— Oxygen sensor heater
— Catalytic converter (TWC)
— Fuel, misfire and evaporative (EVAP) system
Caution
• While performing the Drive Mode, always operate the vehicle in a safe and lawful manner.
• When the M-MDS is used to observe monitor system status while driving, be sure to have another
technician with you, or record the data in the M-MDS using the PID/DATA MONITOR AND RECORD
function and inspect later.
Note
• Vehicle speed and engine speed detected by the PCM may differ from that indicated by the speedometer
and tachometer. Use the M-MDS to monitor vehicle speed.
• If the OBD-II system inspection is not completed during the Drive Mode, the following causes are
considered:
— The OBD-II system detects the malfunction.
— The Drive Mode procedure is not completed correctly.
• Disconnecting the battery will reset the memory. Do not disconnect the battery during and after Drive
Mode.
• The M-MDS can be used at anytime through the course of the Drive Mode to monitor the completion
status. Monitoring can be done by viewing the ON BOARD SYSTEM READINESS menu.
• The OBD monitoring status can be confirmed with the ignition switch operation. During KOEO, the MIL
illuminates for a fail-light inspection for approx. 17 s. The OBD monitoring status is confirmed after the
fail-light inspection.
— If all of the diagnosis is completed even one time, the MIL will continue to illuminate.
— If all of the diagnosis is not completed, the MIL flashes for approx. 7 s, and then it illuminates until the
engine is started.
Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while 01-12
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT[L3 WITH TC].)
3. Remove the front splash shield (RH).
4. Remove the charge air cooler duct. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH
TC].)
5. Remove the drive belt. (See 01-10-3 DRIVE BELT REMOVAL/INSTALLATION[L3 WITH TC].)
6. Remove the P/S oil pump with hose and pipe still connected. Position the P/S oil pump out of the way. (See 06-
14-21 POWER STEERING OIL PUMP REMOVAL/INSTALLATION.)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. Refill the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT[L3 WITH TC].)
10. Inspect for engine coolant leakage. (See 01-12-6
ENGINE COOLANT LEAKAGE INSPECTION[L3
WITH TC].).
1 Water hose
2 Lower radiator hose
3 Thermostat component
4 Gasket
8.0—11.5
End Of Sie 3 {82—117,
71—101}
R 4
8.0—11.5
{82—117,
71—101}
2 1
N·m {kgf·cm, in·lbf}
acxuuw00002011
THERMOSTAT INSPECTION[L3 WITH TC]
id011239801300
1. Inspect the thermostat for the following.
Warning
• During inspection, the thermostat and water are extremely hot and can cause severe burns. Do not
touch the thermostat and water.
• The valve should not open under normal temperature.
• Opening temperature and valve lift
— If there is a malfunction, replace the thermostat.
Thermostat initial-opening temperature
80— 84 °C {176— 183 °F}
Thermostat full-open temperature
97 °C {207 °F}
01-12–11
1871-1U-06B(01-12).fm 12 ページ 2006年3月15日 水曜日 午前10時43分
Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
17—23
{1.8—2.3, 8.0—11.5 N·m
13—16} {82—117 kgf·cm,
71—101 in·lbf}
acxuuw00002063
Warning
• Never remove the cooling system cap or loosen the radiator drain plug while the engine is
running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot
out and cause serious injury. It may also damage the engine and cooling system.
• Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
• When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
01-12–12
1871-1U-06B(01-12).fm 13 ページ 2006年3月15日 水曜日 午前10時43分
2 1
1.8—3.3
5.9—8.3
{18—34,
{61—84, 53—72} 1 16—29}
11 7
2.7—5.0
{28—50,
25—43}
6 9
10
5.9—8.3
{61—84, 53—72}
A
4.9—7.9
{50—80,
44—69}
8
acxuuw00002074
.
01-12–13
1871-1U-06B(01-12).fm 14 ページ 2006年3月15日 水曜日 午前10時43分
End Of Sie B A
WM: COOLANT RESERVE TANK
acxuuw00002065
DLC-2
acxuuw00002068
acxuuw00002069
01-12–14
1871-1U-06B(01-12).fm 15 ページ 2006年3月15日 水曜日 午前10時43分
6. If all the above parts are normal, replace the fan control module.
End Of Sie
WM: RADIATOR
WM: THERMOSTAT
01-12–15
1871-1U-06B(01-13).fm 1 ページ 2006年3月15日 水曜日 午前10時44分
End of Toc
WM: INTAKE-AIR SYSTEM
01-13–1
1871-1U-06B(01-13).fm 2 ページ 2006年3月15日 水曜日 午前10時44分
7
10
4
6 1
acxuuw00000152
.
01-13–2
1871-1U-06B(01-13).fm 3 ページ 2006年3月15日 水曜日 午前10時44分
RESONANCE
CHAMBER
01-13
AIR BYPASS
VALVE
THROTTLE BODY
INTAKE MANIFOLD
THROTTLE COMBUSTION
VALVE CHAMBERS
VARIABLE SWIRL
SHUTTER VALVE
acxuuw00000282
End Of Sie
01-13–3
1871-1U-06B(01-13).fm 4 ページ 2006年3月15日 水曜日 午前10時44分
CHECK VALVE
VARIABLE SWIRL
SOLENOID VALVE
PCV VALVE
acxuuw00000153
End Of Sie
INTAKE AIR SYSTEM MANIFOLD VACUUM INSPECTION[L3 WITH TC]
id011339804200
1. Verify that the intake air hoses are installed securely.
2. Warm up the engine.
3. Disconnect the vacuum hose connected between the check valve and the intake manifold from the intake
manifold and install the vacuum gauge. (See 01-14-19 QUICK RELEASE CONNECTOR REMOVAL/
INSTALLATION[L3 WITH TC])
4. Measure the intake manifold vacuum while idling (no load) using the vacuum gauge.
• If not within the specification, perform the following inspections.
— Accelerator cable play
— Compression pressure (See 01-10-9 COMPRESSION INSPECTION[L3 WITH TC].)
— Air suction (installation areas of throttle body, fuel injector, PCV valve, intake manifold)
Note
• If any air suction exists, the change in engine speed can be made apparent by spraying the penetrant
lubricating spray on the applicable part.
Standard
–71 kPa {–533 mmHg, –21 inHg} or more
End Of Sie
01-13–4
1871-1U-06B(01-13).fm 5 ページ 2006年3月15日 水曜日 午前10時44分
Warning
• A hot engine and intake air system can cause severe burns. Turn off the engine and wait until they
are cool before removing the intake air system.
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and 01-13
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
01-13–5
1871-1U-06B(01-13).fm 6 ページ 2006年3月15日 水曜日 午前10時44分
7.8—10.8
{80—110, 70—95} 7
23.5—35.3 N·m
{2.40—3.59 kgf·m,
17.4—26.0 ft·lbf}
8
18.6—25.5 N·m
{1.90—2.60 kgf·m, 4.9 {50—43}
13.8—18.8 ft·lbf}
7.8—10.8
7.9—10.7 {80—110,
9 {81—109, 70—95}
70—94}
R R
A 7.8—10.8
{80—110,
4.9 {50—43} 70—95}
16
17
0.55—0.85
R {5.7—8.6,
4.9—7.5}
3.9—5.9
{40—60, 35—52}
1
11
23.5—35.3 N·m
2.5—3.4
{2.40—3.59 kgf·m,
{26—34,
17.4—26.0 ft·lbf}
8—11.5 23—30}
14
{82—117,
71—101} R
R
3
10
37.2—51.9 N·m
{3.80—5.29 kgf·m,
13 27.5—38.2 ft·lbf}
7.8—10.8
{80—110, 70—95} 2.5—3.4
{26—34,
R 23—30}
A
7.8—10.8
{80—110, 4
70—95} 2
8—11.5
{82—117,
71—101}
5
15
R
17—23 N·m 12
{1.8—2.3 kgf·m,
13—16 ft·lbf}
18.6—25.5 N·m
{1.90—2.60 kgf·m,
13.8—18.8 ft·lbf}
N·m {kgf·cm, in·lbf}
acxuuw00000205
01-13–6
1871-1U-06B(01-13).fm 7 ページ 2006年3月15日 水曜日 午前10時44分
01-13–7
1871-1U-06B(01-13).fm 8 ページ 2006年3月15日 水曜日 午前10時44分
Caution
• When removing the cowl grille, a part or tool may hit the edge of the windshield and could damage
it. Protect the windshield by covering it with a clean rag to prevent damage to the windshield.
OIL PIPE
OIL PIPE
OIL PIPE
acxuuw00000207
acxuuw00000285
01-13–8
1871-1U-06B(01-13).fm 9 ページ 2006年3月15日 水曜日 午前10時44分
23.5—35.3 N·m
{2.40—3.59 kgf·m,
17.4—26.0 ft·lbf}
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
acxuuw00000209
5. Install the oil pipes and, insert the oil hose until it
reaches the stopper.
7.8—10.8 {80—110, 70—95}
OIL HOSE
STOPPER
23.5—35.3 N·m
{2.40—3.59 kgf·m,
17.4—26.0 ft·lbf}
7.8—10.8
{80—110, 70—95}
N·m {kgf·cm, in·lbf}
acxuuw00000210
01-13–9
1871-1U-06B(01-13).fm 10 ページ 2006年3月15日 水曜日 午前10時44分
Tightening torque
7.8— 10.8 N·m {80— 110 kgf·cm, 70— 95 in·lbf}
1—3 mm
{0.04—0.11 in}
(36˚)
A
(95˚)
DETAIL A
B
WASTEGATE
CONTROL
SOLENOID
VALVE
(190˚)
acxuuw00000211
2. Install the hose as shown in the figure.
"
acxuuw00000284
Caution
• Before assembling the air cleaner, verify that the rubber mounts have not fallen off from the air
cleaner bracket (3 locations).
• Always install the air cleaner case using the following procedure.
Note
• When inserting the rubber mounts into the air cleaner case, soapy water can be applied.
1. Verify that the rubber mounts are set in the air cleaner bracket (3 locations).
2. Install the projections on the frame side (2 locations).
3. Verify that the projections on the frame side are installed securely.
4. Install the projection on the engine side (remaining location).
5. Verify that the projection on the engine side installed securely.
01-13–10
1871-1U-06B(01-13).fm 11 ページ 2006年3月15日 水曜日 午前10時44分
id011339800800
1. Remove the air cleaner element. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH
TC].)
2. Verify that the air cleaner element surface is free of dirt.
• If there is dirt, use an air gun or similar tool to clean the element.
• If the replacement time limit has passed, replace the element.
End Of Sie 01-13
CHARGE AIR COOLER INSPECTION[L3 WITH TC]
WM: CHARGE AIR COOLER
id011339800900
1. Remove the charge air cooler duct.
2. Remove the charge air cooler cover. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH
TC].)
3. Remove the charge air cooler. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
4. Remove the air bypass valve. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
5. Plug ports A and B.
6. Verify that there is no air leakage when air is sent
from port C.
• If there is leakage, replace the charge air
cooler.
End Of Sie
WM: INTAKE-AIR SYSTEM
PORT A
PORT B
PORT C
acxuuw00000509
PORT A
ROD
Approx. value
VALVE OPERATION CHARACTERISTIC
7.5 {0.30}
ROD STROKE
(mm {in}) VALVE
OPEN
0.5 {0.02}
—P1 —P2
VACUUM
P1=49.3—65.3 kpa {370—489 mmHg, 15.0—19.2 inHg}
P2=86.1—115.3 kpa {646—864 mmHg, 25.5—34.0 inHg}
acxuuw00000286
01-13–11
1871-1U-06B(01-13).fm 12 ページ 2006年3月15日 水曜日 午前10時44分
End Of Sie
THROTTLE ACTUATOR INSPECTION[L3 WITH TC]
WM: THROTTLE ACTUATOR
id011339801300
Note
• Perform the following inspection only when directed.
Resistance Inspection
1. Disconnect the negative battery cable.
2. Disconnect the throttle body connector.
3. Measure the resistance between the throttle actuator terminals using a tester.
• If not as specified, replace the throttle body. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/
INSTALLATION[L3 WITH TC].)
• If as specified, carry out the “Circuit Open/Short Inspection”.
Specification
Ambient temperature (°C {°F}) Resistance (ohm)
Approx. 20 {68} 0.3— 100
F E
acxuuw00000024
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000025
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— Throttle actuator terminal F and PCM terminal 2A
— Throttle actuator terminal E and PCM terminal 2B
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— Throttle actuator terminal F and power supply
— Throttle actuator terminal F and ground
— Throttle actuator terminal E and power supply
— Throttle actuator terminal E and ground
End Of Sie
WM: VARIABLE TUMBLE SHUTTER VALVE ACTUATOR
01-13–12
1871-1U-06B(01-13).fm 13 ページ 2006年3月15日 水曜日 午前10時44分
End Of Sie
VARIABLE SWIRL SOLENOID VALVE INSPECTION[L3 WITH TC]
WM: VARIABLE TUMBLE SOLENOID VALVE
id011339801100
1. Remove the variable swirl solenoid valve.
2. Inspect the airflow between the ports under the
following conditions.
• If not as specified, replace the variable swirl B A
control solenoid valve. B A
• If as specified, carry out the “Circuit Open/
Short Inspection”.
: Continuity : Airflow
Terminal Port
Step
A B A B
1
acxuuw00000026
2 B+ GND
acxuuw00000027
B A
acxuuw00000028
FUSE BOX
(MAIN RELAY)
B
FRONT
A E
D
acxuuw00002335
01-13–13
1871-1U-06B(01-13).fm 14 ページ 2006年3月15日 水曜日 午前10時44分
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000029
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— Variable swirl solenoid valve terminal B and PCM terminal 2AS
— Variable swirl solenoid valve terminal A and main relay terminal E
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— Variable swirl solenoid valve terminal A and body ground
— Variable swirl solenoid valve terminal B and power supply
— Variable swirl solenoid valve terminal B and body ground
End Of Sie
WASTEGATE CONTROL SOLENOID VALVE INSPECTION[L3 WITH TC]
WM: AIR CHARGING PRESSURE COMPONENT
id011339800600
1. Remove the wastegate control solenoid valve. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/
INSTALLATION[L3 WITH TC].)
2. Inspect the airflow between the ports under the
following conditions.
• If not as specified, replace the wastegate B A
control solenoid valve. B A
• If as specified, carry out the “Circuit Open/
Short Inspection”.
: Continuity : Airflow
Terminal Port
Step
A B A B
1
acxuuw00000030
2 B+ GND
acxuuw00000031
01-13–14
1871-1U-06B(01-13).fm 15 ページ 2006年3月15日 水曜日 午前10時44分
WASTEGATE CONTROL
SOLENOID VALVE
WIRING HARNESS SIDE CONNECTOR
01-13
B A
acxuuw00000032
FUSE BOX
(MAIN RELAY)
B
FRONT
A E
D
acxuuw00002335
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000033
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— Wastegate control solenoid valve terminal B and PCM terminal 2AA
— Wastegate control solenoid valve terminal A and main relay terminal E
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— Wastegate control solenoid valve terminal A and body ground
— Wastegate control solenoid valve terminal B and power supply
— Wastegate control solenoid valve terminal B and body ground
End Of Sie
01-13–15
1871-1U-06B(01-13).fm 16 ページ 2006年3月15日 水曜日 午前10時44分
49 H080 740A
WASTEGATE
ACTUATOR
ROD
PLUG
acxuuw00000663
01-13–16
1871-1U-06B(01-13).fm 17 ページ 2006年3月15日 水曜日 午前10時44分
Note
• If there is contact between the turbine wheel
and turbine housing, there may be cracks,
damage, or bending on the blade end area.
B
• If there are cracks, damage, or bending on
the turbine wheel, verify the following after
replacing the turbocharger.
— Intake air/exhaust system related
components TURBINE WHEEL
— Oil pipe damage
End Of Sie
WM: ACCELERATOR PEDAL
acxuuw00000478
acxuuw00002531
01-13–17
1871-1U-06B(01-14).fm 1 ページ 2006年3月15日 水曜日 午前10時45分
End of Toc
WM: FUEL SYSTEM
01-14–1
1871-1U-06B(01-14).fm 2 ページ 2006年3月15日 水曜日 午前10時45分
3
5
1
7
6
acxuuw00000154
.
01-14–2
1871-1U-06B(01-14).fm 3 ページ 2006年3月15日 水曜日 午前10時45分
3
01-14
acxuuw00000155
End Of Sie
FUEL SYSTEM DIAGRAM[L3 WITH TC]
id011439800200
HIGH PRESSURE
FUEL PUMP
FUEL TANK
PRESSURE REGULATOR
FUEL INJECTOR
FUEL PRESSURE
FUEL PUMP SENSOR
D6U114ZWC006
End Of Sie
01-14–3
1871-1U-06B(01-14).fm 4 ページ 2006年3月15日 水曜日 午前10時45分
Warning
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following “Fuel
Line Safety Procedure”.
• A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before performing work on the fuel system, discharge static electricity by touching
the vehicle body.
Note
• Fuel in the fuel system is under high pressure even when the engine is not running.
1. Remove the fuel-filler cap and release the pressure in the fuel tank.
2. Remove the fuel pump relay.
3. Start the engine.
4. After the engine stalls, crank the engine several
times. MAIN FUSE BLOCK
5. Turn the ignition switch to the LOCK position.
6. Install the fuel pump relay.
End Of Sie
acxuuw00000262
Warning
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. When installing the fuel hose, perform “Fuel Leakage Inspection” described below.
Warning
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Always carry out the following procedure with the engine stopped.
• A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before performing work on the fuel system, discharge static electricity by touching
the vehicle body.
Caution
• Connecting to the wrong check connector terminal may cause a malfunction. Carefully connect
only to the specified terminal.
01-14–4
1871-1U-06B(01-14).fm 5 ページ 2006年3月15日 水曜日 午前10時45分
Warning
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death.
Fuel can also irritate skin and eyes. To prevent this, always complete the “BEFORE REPAIR
PROCEDURE”. (See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
Caution
• Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using cloth or soft brush, and make sure that it is free
of foreign material.
Caution
• The quick release connector may be damaged if the tab is turned too far. Do not turn the tab over
the stopper.
4. Disconnect the quick release connector from the fuel tank. (See01-14-19 QUICK RELEASE CONNECTOR
REMOVAL/INSTALLATION[L3 WITH TC].)
5. Push the SST quick release connector into the fuel pipe and plastic fuel hose into the SST until a click is heard.
01-14–5
1871-1U-06B(01-14).fm 6 ページ 2006年3月15日 水曜日 午前10時45分
49 N013 101A
49 N013 102A
acxuuw00000248
7. Connect the vacuum hose to the intake manifold that connecting to the brake booster.
8. Connect the negative battery cable.
9. Start the engine and let it idle. Measure the fuel line pressure.
• If not as specified, inspect the following:
Zero or low
— FP circuit
— FP
— Fuel line (clogged)
— Fuel leakage inside pressure regulator
High
— Pressure regulator for high pressure cause
High Pressure Line (From the High Pressure Fuel Pump to the Fuel Injector)
1. Inspect the fuel pressure sensor. (See01-40-35 FUEL PRESSURE SENSOR REMOVAL/INSTALLATION[L3
WITH TC].)
2. Inspect the high pressure fuel pump. (See01-40-35 FUEL PRESSURE SENSOR REMOVAL/
INSTALLATION[L3 WITH TC].)
End Of Sie
WM: FUEL TANK
01-14–6
1871-1U-06B(01-14).fm 7 ページ 2006年3月15日 水曜日 午前10時45分
Warning
• Repairing a fuel tank that has not been properly steam-cleaned can be dangerous. Explosion or
fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel pump unit when removing or installing. 01-14
• A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before draining fuel, make sure to discharge static electricity by touching the
vehicle body.
Caution
• Disconnecting/connecting the quick release connector without cleaning it may cause damage to
the fuel pipe and quick release connector. Always clean the quick release connector joint area
before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of
foreign material.
01-14–7
1871-1U-06B(01-14).fm 8 ページ 2006年3月15日 水曜日 午前10時45分
A
9.0—13.0 N·m
B {92—132 kgf·cm, 80—115 in·lbf}
4
RIVET
43.1—60.8
{4.40—6.20, 31.8—44.8}
1
RIVET
43.1—60.8
{4.40—6.20, 31.8—44.8}
43.1—60.8
{4.40—6.20, 31.8—44.8}
N·m {kgf·m,ft·lbf}
acxuuw00000195
01-14–8
1871-1U-06B(01-14).fm 9 ページ 2006年3月15日 水曜日 午前10時45分
Caution
• Be careful not to damage the fuel tank when removing the rivet. If the fuel tank is damaged, it may
cause fuel leakage. 01-14
Note
• The insulator is installed using rivets.
• When resin stalling the rivet, install the same rivet or M5 bolt and nut.
INSULATOR
acxuuw00000260
DRILL
FLANGE
acxuuw00000261
CLAMP
TIGHTENING AREA
acxuuw00000265
01-14–9
1871-1U-06B(01-14).fm 10 ページ 2006年3月15日 水曜日 午前10時45分
45°
45°
VIEW B
acxuuw00000266
Caution
• Disconnecting/connecting the quick release connector without cleaning it may cause damage to
the fuel pipe and quick release connector. Always clean the quick release connector joint area
before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of
foreign material.
Note
• This inspection is for fuel shut-off valve and rollover valve integrated in the fuel tank.
1. Disconnect the quick release connector and the fuel pump unit connector. (See01-14-11 FUEL PUMP UNIT
REMOVAL/INSTALLATION[L3 WITH TC].)
2. Remove the fuel tank with the fuel pump unit. (See01-14-7 FUEL TANK REMOVAL/INSTALLATION[L3 WITH
TC].)
3. Plug the port as shown in the figure.
4. Level the fuel tank. A
B PLUG
PLUG
FUEL PUMP UNIT
acxuuw00000122
01-14–10
1871-1U-06B(01-14).fm 11 ページ 2006年3月15日 水曜日 午前10時45分
Warning
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, before performing the fuel pump unit 01-14
removal/installation, always complete the “Fuel Leak Inspection After Fuel Pump Unit
Installation”.
• A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before draining fuel, make sure to discharge static electricity by touching the
vehicle body.
Caution
• Because the fuel tank is constructed such that the fuel level is higher than the installation surface
of the fuel pump, fuel leakage could occur. If the fuel gauge indicates a fuel level of half or more,
perform the following Steps 1-6 to drain approx. 10 L {11 US gal, 8.8 lmp gal} of fuel.
• Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.
• To prevent the SST from coming off the fuel pump cap while performing the work, always perform
the removal/installation procedure with 2 people. One person presses the SST against cap from
directly above, while the other person rotates the SST.
1. Complete the “BEFORE REPAIR PROCEDURE”. (See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH
TC].)
2. Remove the rear seat cushion.
3. Remove the service hole cover.
SERVICE HOLE COVER
acxuuw00000510
HOSE
acxuuw00000181
01-14–11
1871-1U-06B(01-14).fm 12 ページ 2006年3月15日 水曜日 午前10時45分
Caution
• Short the specified terminals because
shorting the wrong terminal of the main
fuse block may cause malfunctions.
DLC-2
acxuuw00000288
2. Using a jumper wire, short fuel pump relay
terminals C and D in the main fuse block. MAIN FUSE BLOCK
(FUEL PUMP RELAY)
3. Connect the negative battery cable and
operate the fuel pump. A E
Caution C
• The fuel pump could be damaged if it is D
operated (fuel pump idling) while there is
no fuel in the fuel tank. Verify the amount
of fuel being discharged from the hose
and stop operation of the fuel pump
when essentially no fuel is being
acxuuw00000183
discharged.
1
6
5 R
2
4
3
acxuuw00000289
01-14–12
1871-1U-06B(01-14).fm 13 ページ 2006年3月15日 水曜日 午前10時45分
Warning
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel pump unit when removing or installing.
End Of Sie
R
R
2
3
R
5
4
R
acxuuw00002338
FUEL PUMP UNIT INSPECTION[L3 WITH TC]
id011439801100
Continuity Inspection
Note
• Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Remove the rear seat cushion.
3. Remove the service hole cover.
4. Disconnect the fuel pump unit connector.
SERVICE HOLE COVER
acxuuw00000510
5. Inspect for continuity between fuel pump unit
connector terminals B and D. FUEL PUMP UNIT PUMP
• If there is no continuity, replace the fuel pump SIDE CONNECTOR
body.
• If as specified, carry out the “Circuit Open/
Short Inspection”. C A
D B
acxuuw00000034
01-14–13
1871-1U-06B(01-14).fm 14 ページ 2006年3月15日 水曜日 午前10時45分
A E
C A C
D B
D
acxuuw00000035
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— Fuel pump unit terminal B and fuel pump relay terminal A
— Fuel pump unit terminal D and body ground
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— Fuel pump unit terminal B and power supply
— Fuel pump unit terminal B and body ground
— Fuel pump unit terminal D and power supply
Warning
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Always carry out the following procedure with the engine stopped.
Caution
• Disconnecting/connecting the quick release connector without cleaning it may cause damage to
the fuel pipe and quick release connector. Always clean the quick release connector joint area
before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of
foreign material.
Note
• Perform the following test only when directed.
1. Complete the “BEFORE REPAIR PROCEDURE”. (See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH
TC].)
2. Disconnect the negative battery cable.
3. Remove the battery and battery tray.
Caution
• The quick release connector may be damaged if the tab is bent excessively. Do not expand the tab
over the stopper.
4. Disconnect the quick release connector from the fuel tank. (See01-14-19 QUICK RELEASE CONNECTOR
REMOVAL/INSTALLATION[L3 WITH TC].)
5. Turn the lever 90° against the hose of the SST to
plug the SST outlet. 49 B019 901B
6. Push the SST quick release connector into the
fuel pipe until a click is heard. 49 N013 101A
LEVER
7. Set the fuel hose into a container to avoid fuel TO FUEL TANK
spills.
49 N013 102A
acxuuw00000036
01-14–14
1871-1U-06B(01-14).fm 15 ページ 2006年3月15日 水曜日 午前10時45分
Tightening torque
4.2— 6.2 N·m {43— 63 kgf·cm, 38— 54 in·lbf} 2
6. Connect the fuel pump resistor connector.
End Of Sie
acxuuw00002403
01-14–15
1871-1U-06B(01-14).fm 16 ページ 2006年3月15日 水曜日 午前10時45分
End Of Sie
acxuuw00002331
Caution
• Do not disassemble the high pressure fuel pump.
• Do not scratch or damage the fuel sealing surface of the high and low fuel ports.
• When removing the high pressure fuel pipe, secure the joint (pump side) so that it dose not rotate,
and loosen the screw (pipe side).
Note
• If the high pressure fuel pump is removed, replace the O-ring with a new one.
1. Complete the “BEFORE REPAIR PROCEDURE”. (See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH
TC].)
2. Disconnect the negative battery cable.
3. Remove the charge air cooler duct.
4. Disconnect the spill valve control solenoid valve connector.
5. Disconnect the quick release connector on the high pressure fuel pump. (See01-14-19 QUICK RELEASE
CONNECTOR REMOVAL/INSTALLATION[L3 WITH TC].)
6. Remove the battery and battery tray. (See01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].)
7. Remove the air duct. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC])
01-14–16
1871-1U-06B(01-14).fm 17 ページ 2006年3月15日 水曜日 午前10時45分
JOINT NUT
HIGH PRESSURE
WATER OUTLET CASE LINE PIPE
INSTALLATION BOLT
acxuuw00000291
(1) Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.
(2) Loosen the high pressure line pipe installation nut.
9. Drain engine coolant. (See01-12-5 ENGINE COOLANT REPLACEMENT[L3 WITH TC].)
10. Loosen the water outlet case installation bolts securing the high pressure line pipe.
11. Remove the high pressure fuel pump.
8.5—11.5 N·m
{87—117 kgf·cm,
76—101 in·lbf}
OIL
O-RING R
OIL
acxuuw00000292
12. Remove the high pressure fuel pump cover.
13. Tighten the bolts on the high pressure fuel pump R 17—23 N·m
{1.8—2.3 kgf·m,
cover. 13—16 ft·lbf}
Tightening torque
17— 23 N·m {1.8— 2.3 kgf·m, 13— 16 ft·lbf}
acxuuw00000293
01-14–17
1871-1U-06B(01-14).fm 18 ページ 2006年3月15日 水曜日 午前10時45分
Tightening torque
8.5— 11.5 N·m {87— 117 kgf·cm, 76— 101 in·lbf}
Warning
• If the high pressure fuel pump joint nut is loosened, fuel leakage may occur resulting in death or
serious injury, or damage to the equipment or the vehicle. Fuel can also irritate the skin and eyes.
When installing the high pressure line pipe, always tighten the high pressure line pipe installation
nut while fixing the high pressure fuel pump joint nut with a wrench. If the high pressure fuel pump
joint nut has rotated, replace the high pressure fuel pump with a new one.
JOINT NUT
HIGH PRESSURE
WATER OUTLET CASE LINE PIPE
INSTALLATION BOLT
acxuuw00000294
(1) Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.
(2) Tighten the high pressure line pipe installation nut.
Tightening torque
23.5— 35.5 N·m {2.40— 3.59 kgf·m, 17.4— 26.0 ft·lbf}
Tightening torque
8— 11.5 N·m {82— 117 kgf·cm, 71— 101 in·lbf}
17. Install the quick release connector. (See01-14-19 QUICK RELEASE CONNECTOR REMOVAL/
INSTALLATION[L3 WITH TC].)
01-14–18
1871-1U-06B(01-14).fm 19 ページ 2006年3月15日 水曜日 午前10時45分
Note
• Perform the following inspection only when directed.
• The following vacuum values are indicated by relative pressure from the fuel pressure sensor.
1. Verify that the fuel pressure sensor is normal. (See01-40-35 FUEL PRESSURE SENSOR INSPECTION[L3
WITH TC].)
01-14
2. Connect the M-MDS to the DLC-2.
3. Turn the ignition switch to the ON position (Engine
off).
4. Select the FUEL_PRES, and LOAD, RPM PIDs
on the M-MDS.
Caution
• If the engine is run at a high speed, it
could be damaged. When racing the
engine, do not race it up to 6,700 rpm or
more.
DLC-2
acxuuw00000263
5. After the LOAD PID is 60% or more while the
engine is raced with the accelerator pedal fully
depressed, verify that the FUEL_PRES PID is approx. 11.5Mpa.
— If not as verified, replace the high pressure fuel pump.
End Of Sie
QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION[L3 WITH TC]
WM: QUICK RELEASE CONNECTOR
id011439801700
Warning
• Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause
serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this,
always complete the “Fuel Line Safety Procedure”, while referring to the “BEFORE SERVICE
PRECAUTION”.
C
A
B A
B B
C
C
acxuuw00000053
01-14–19
1871-1U-06B(01-14).fm 20 ページ 2006年3月15日 水曜日 午前10時45分
Caution
• The quick release connector may be damaged if the release tab is bent excessively. Do not expand
the release tab over the stopper.
Note
• The fuel hose can be removed by pushing it to the pipe side to release the lock.
RELEASE TAB
STOPPER
acxuuw00000054
3. Pull out the fuel hose straight from the fuel pipe
and disconnect it.
acxuuw00000055
acxuuw00000056
01-14–20
1871-1U-06B(01-14).fm 21 ページ 2006年3月15日 水曜日 午前10時45分
Caution
• Be careful not to damage the pipe when unlocking the retainer.
Note
• When removing the quick connector, either SST 49 E042 001 or 49 N013 103A.
01-14
When using SST 49 N013 103A
1. Follow “BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing
any work operations. (See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
2. Insert the SST into the quick release connector.
3. Pull out the fuel hose straight from the fuel pipe
and disconnect it.
QUICK RELEASE CONNECTOR
4. Cover the disconnected quick release connector
and fuel pipe with vinyl sheeting or a similar
material to prevent it from scratches or dirt.
FUEL PIPE
49 N013 103A
acxuuw00002337
Note
• If the quick release connector is removed, replace the retainer with a new one.
1. Follow “BEFORE SERVICE PRECAUTION” and remove dirt from the connecting surfaces before performing
any work operations. (See01-14-4 BEFORE REPAIR PROCEDURE[L3 WITH TC].)
Note
• The retainer is attached to the pipe even after the connector is disconnected.
Note
• The quick release connector can be
removed by pushing the center of the
retainer tabs.
R RETAINER
acxuuw00000058
01-14–21
1871-1U-06B(01-14).fm 22 ページ 2006年3月15日 水曜日 午前10時45分
QUICK RELEASE
CONNECTOR
acxuuw00000059
acxuuw00000056
Type A Installation
Note
• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.
• A checker tab is integrated with the quick
release connector for new fuel hoses and
evaporative hoses. Remove the checker tab CHECKER TAB
from the quick release connector after the
connector is completely engaged with the
fuel pipe.
Note
• If the quick release connector does not move at all, disconnect it, verify that the O-ring is not damaged or
has not slipped, and then reconnect the quick release connector.
4. Lightly pull and push the quick release connector a few times by hand, and then verify that it can move 2.0—
3.0 mm {0.08— 0.12 in} and is connected securely.
5. Inspect all related parts by performing “AFTER REPAIR PROCEDURE”. (See01-14-4 AFTER REPAIR
PROCEDURE[L3 WITH TC].)
01-14–22
1871-1U-06B(01-14).fm 23 ページ 2006年3月15日 水曜日 午前10時45分
Note
• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.
• A checker tab is integrated with the quick
release connector for new fuel hoses and
evaporative hoses. Remove the checker tab CHECKER TAB
from the quick release connector after the 01-14
connector is completely engaged with the
fuel pipe.
Caution
• Be sure to replace the retainer with a new
one to prevent gas leakage. NEW FUEL HOSE
• To prevent evaporative gas leakage, be
sure not to damage the connecting part
acxuuw00000060
between the charcoal canister and pipe,
and the locks between the quick release
connector and retainer. If any of them are damaged, replace the charcoal canister or hose with a
new one.
Type C Installation
Note
• If the quick release connector O-ring is damaged or has slipped, replace the fuel hose.
1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.
• If there is any malfunction, replace it with a new one.
2. Install the quick release connector.
• Insert the fuel pipe straight to the end of the
quick release connector. 2
• Push down the retainer using a finger.
— If the retainer cannot be pushed down,
push the fuel pipe further to the quick
release connector.
1
3. Lightly pull and push the quick release connector
a few times by hand, and then verify that it is
connected securely.
4. Inspect all related parts by performing “AFTER
REPAIR PROCEDURE”. (See01-14-4 AFTER
acxuuw00000061
REPAIR PROCEDURE[L3 WITH TC].)
End Of Sie
FUEL INJECTOR REMOVAL/INSTALLATION[L3 WITH TC]
WM: FUEL INJECTOR
id011439800600
Caution
• Disconnecting/connecting the quick release connector without cleaning it may cause damage to
the fuel pipe and quick release connector. Always clean the quick release connector joint area
before disconnecting/connecting using a cloth or soft brush, and make sure that it is free of
foreign material.
Note
• When the fuel pressure sensor replaces, replace a new fuel delivery pipe with a new fuel pressure
sensor.(See 01-14-23 FUEL INJECTOR REMOVAL/INSTALLATION[L3 WITH TC])
01-14–23
1871-1U-06B(01-14).fm 24 ページ 2006年3月15日 水曜日 午前10時45分
8—11.5 N·m
17—23 21.5—25.5
{82—117 kgf·cm,
{1.8—2.3, 13—16} {2.20—2.60, 15.9—18.8}
71—101 in·lbf}
2
R
1
17—23
{1.8—2.3,
R 13—16}
5
16—24
SST {1.7—2.4, 12—17}
4
3
N·m {kgf·m, ft·lbf}
acxuuw00000267
JOINT NUT
HIGH PRESSURE
WATER OUTLET CASE LINE PIPE
INSTALLATION BOLT
acxuuw00000268
(1) Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.
(2) Loosen the high pressure line pipe installation nut.
3. Remove the high pressure line pipe.
01-14–24
1871-1U-06B(01-14).fm 25 ページ 2006年3月15日 水曜日 午前10時45分
Note
• Depending on the driving conditions, carbon may accumulate on the inserted part of the fuel injector,
causing the fuel injector to stick. Remove the fuel injector using the following procedure.
Caution
• If the SST slips while ratcheting up the
fuel injector, the fuel injector or 49 G013 101
surrounding parts could be damaged.
Press fit the SST to the fuel injector firmly
and operate carefully. DEEP OPENING
• When ratcheting up the fuel injector, the SIDE
fuel injector connector may contact the
cylinder head and damage the fuel
injector. Ratchet up the fuel injector so CONNECTOR
that the fuel injector connector does not SIDE R OIL
GASKET
R
OIL
acxuuw00000269
Note
• If fuel injector No.3 contacts the oil
separator, cut the tab on the oil separator as
shown in the figure. Carefully cut the tab so
that the oil separator is not deformed or 6 mm {0.2 in}
TAB
damaged, with no clearance on the mating OR LESS
surfaces of the oil separator and engine.
PCV VALVE
acxuuw00000270
2. Keep ratcheting the SST so that the fuel injector becomes free enough to ratchet up without using the SST.
Caution
• Do not apply excessive force to the fuel injector connector because the fuel injector could be
damaged.
Warning
• If foreign material such as metal shavings penetrates the fuel injector installation hole on the
cylinder block, the engine could be damaged. Remove all foreign material and cap the fuel injector
installation hole after removing the fuel injector.
5. Clean the fuel injector and around the insertion hole using a vacuum cleaner.
01-14–25
1871-1U-06B(01-14).fm 26 ページ 2006年3月15日 水曜日 午前10時45分
Tightening torque 4 2 1 3 5
17— 23 N·m {1.8— 2.3 kgf·m, 13— 16 ft·lbf}
acxuuw00000271
1
2
3 4
acxuuw00000272
Tightening torque
17— 23 N·m {1.8— 2.3 kgf·m, 13— 16 ft·lbf}
01-14–26
1871-1U-06B(01-14).fm 27 ページ 2006年3月15日 水曜日 午前10時45分
01-14
JOINT NUT
HIGH PRESSURE
WATER OUTLET CASE LINE PIPE
INSTALLATION BOLT
acxuuw00000273
(1) Fix the joint nut with a wrench on the high pressure fuel pump side as shown in the figure.
(2) Tighten the high pressure line pipe installation nut.
Tightening torque
23.5— 35.5 N·m {2.40— 3.61 kgf·m, 17.4— 26.1 ft·lbf}
Tightening torque
17— 23 N·m {1.8— 2.3 kgf·m, 13— 16 ft·lbf}
End Of Sie
FUEL INJECTOR INSPECTION[L3 WITH TC]
id011439800700
Operation Test
1. Carry out the “Fuel Injector Operation Inspection”. (See01-03-78 ENGINE CONTROL SYSTEM OPERATION
INSPECTION[L3 WITH TC].)
• If not as specified, perform the further inspection for the fuel injectors.
Resistance Inspection
Note
• Perform the following procedure only when directed.
01-14–27
1871-1U-06B(01-14).fm 28 ページ 2006年3月15日 水曜日 午前10時45分
A B
acxuuw00000039
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000040
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— No.1 cylinder fuel injector terminal A and PCM terminal 2BB
— No.2 cylinder fuel injector terminal A and PCM terminal 2BC
— No.3 cylinder fuel injector terminal A and PCM terminal 2BD
— No.4 cylinder fuel injector terminal A and PCM terminal 2AZ
— No.1 cylinder fuel injector terminal B and PCM terminal 2BG
— No.2 cylinder fuel injector terminal B and PCM terminal 2BH
— No.3 cylinder fuel injector terminal B and PCM terminal 2BH
— No.4 cylinder fuel injector terminal B and PCM terminal 2BG
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— No.1 cylinder fuel injector terminal A and power supply
— No.1 cylinder fuel injector terminal A and body ground
— No.2 cylinder fuel injector terminal A and power supply
— No.2 cylinder fuel injector terminal A and body ground
— No.3 cylinder fuel injector terminal A and power supply
— No.3 cylinder fuel injector terminal A and body ground
— No.4 cylinder fuel injector terminal A and power supply
— No.4 cylinder fuel injector terminal A and body ground
— No.1 cylinder fuel injector terminal B and power supply
— No.1 cylinder fuel injector terminal B and body ground
— No.2 cylinder fuel injector terminal B and power supply
— No.2 cylinder fuel injector terminal B and body ground
— No.3 cylinder fuel injector terminal B and power supply
— No.3 cylinder fuel injector terminal B and body ground
— No.4 cylinder fuel injector terminal B and power supply
— No.4 cylinder fuel injector terminal B and body ground
End Of Sie
PRESSURE REGULATOR INSPECTION[L3 WITH TC]
WM: PRESSURE REGULATOR
id011439800800
Note
• Due to the adoption of the mechanical returnless fuel system, the pressure regulator cannot be inspected
separately.
1. Perform “FUEL LINE PRESSURE INSPECTION”. (See 01-14-5 FUEL LINE PRESSURE INSPECTION[L3
WITH TC].)
End Of Sie
01-14–28
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
EXHAUST SYSTEM [L3 WITH TC]
01-15 EXHAUST SYSTEM [L3 WITH TC]
EXHAUST SYSTEM INSPECTION Exhaust Manifold Insulator (Upper)
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-15–1 Removal Note . . . . . . . . . . . . . . . . . . . 01-15–3
EXHAUST SYSTEM WU-TWC Removal Note . . . . . . . . . . . . 01-15–3
REMOVAL/INSTALLATION Exhaust Manifold
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-15–2 Installation Note . . . . . . . . . . . . . . . . . 01-15–4
Seal Ring Removal Note . . . . . . . . . . . 01-15–3 WU-TWC Installation Note . . . . . . . . . . 01-15–4 01-15
HO2S Removal Note . . . . . . . . . . . . . . 01-15–3 Seal Ring Installation Note . . . . . . . . . . 01-15–4
End of Toc
EXHAUST SYSTEM INSPECTION[L3 WITH TC]
WM: EXHAUST SYSTEM
id011539800100
1. Start the engine and inspect each exhaust system component for exhaust gas leakage.
• If there is leakage, repair or replace if necessary.
End Of Sie
01-15–1
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
EXHAUST SYSTEM [L3 WITH TC]
EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]
id011539800200
Warning
• A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they
are cool before removing the exhaust system.
1. Disconnect the negative battery cable.
2. Remove the charge air cooler duct.
3. Remove the charge air cooler cover. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH
TC])
4. Remove the charge air cooler. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC])
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
43—64
{4.4—6.5, 32—47} 8
43—64
{4.4—6.5, 32—47} TURBOCHARGER
R 14
R
7.8—10.8 N·m
15 {80—110 kgf·cm,
10 70—95 in·lbf}
7 29—49
6 {3.0—4.9, 22—36}
SST
7.8—10.8 N·m 29—49 9 11
{80—110 kgf·cm, {3.0—4.9, 22—36}
70—95 in·lbf} 13
SST 4
R R A
SST
2
38—51 R
{3.9—5.2, 29—37} 5
SST
12
38—51
{3.9—5.2, 29—37}
38—51
{3.9—5.2, 29—37}
3 1
acxuuw00002568
.
FLATHEAD SCREWDRIVER
acxuuw00002569
49 L018 001
49 L018 001
acxuuw00000172
4WD
1. Remove the cowl grille.
2. Remove the windshield wiper motor.
3. Remove the cowl panel. (See 09-10-13 COWL PANEL REMOVAL/INSTALLATION)
4. Remove the generator duct. (See 01-17-4 GENERATOR REMOVAL/INSTALLATION[L3 WITH TC])
5. Set the generator out of the way.
6. Remove the WU-TWC.
01-15–3
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
EXHAUST SYSTEM [L3 WITH TC]
Exhaust Manifold Installation Note
1. Tighten the exhaust manifold installation nuts in
the order shown.
Tightening torque
43— 64 N·m {4.4— 6.5 kgf·m, 32— 47 ft·lbf}
8 2 3
7
9
10
6 4 1 5
acxuuw00000175
Tightening torque
38— 51 N·m {3.9— 5.2 kgf·m, 29— 37 ft·lbf}
Caution
• If installation is performed without using the SST, the seal ring will be damaged and deformed,
resulting in an incorrect installation. Always use the SST to install the seal ring.
FLANGE
acxuuw00002570
01-15
49 G040 001 FLANGE
acxuuw00002571
3. Press in the seal ring by tapping the SST using a
plastic hammer until the seal ring contacts the 49 G040 001
flange.
End Of Sie
acxuuw00002572
End of Toc
WM: EVAP CONTROL SYSTEM
acxuuw00000176
.
1
acxuuw00000177
.
1 WU-TWC 2 TWC
01-16–2
1871-1U-06B(01-16).fm 3 ページ 2006年3月15日 水曜日 午前10時48分
01-16
1
2
acxuuw00000178
.
End Of Sie
01-16–3
1871-1U-06B(01-16).fm 4 ページ 2006年3月15日 水曜日 午前10時48分
CHECK VALVE
CHARCOAL CANISTER
AIR FILTER
EGR VALVE
FUEL SHUT-OFF ROLLOVER VALVE
VALVE
PCV VALVE
acxuuw00000062
End Of Sie
FUEL-FILLER CAP INSPECTION[L3 WITH TC]
WM: FUEL FILLER CAP
id011639801300
Leakage Inspection
1. Perform the following SST (Evaporative Emission System Tester 134-01049) self-test:
Note
• If the tester does not work correctly during self-test, refer to the tester operators manual for more detailed
procedures.
(1) Verify that the gas cylinder valve is closed and the control valve located on the tester is in the TEST
position. All tester displays should be off at this time.
(2) Connect the long hose (part of SST) to the
tester.
(3) Connect the manifold assembly (part of SST)
to the long hose as shown.
(4) Open the gas cylinder valve and verify the gas
cylinder regulator left gauge reads 69— 82
kPa {0.71— 0.83 kgf/cm2, 10— 12 psi}
(preset at factory).
• If not, refer to the tester operators manual
to contact tester manufacturer.
(5) Press the ON/OFF switch to turn on the SST
and make sure the left display reads 0.0. acxuuw00002343
(6) Turn the control valve on the tester to the FILL
position.
(7) Verify the left display reading is within 13.9 to 14.0 in of water.
• If not, adjust the pressure using the regulator knob located on the right side of the tester.
(8) Turn the control valve to TEST position and press the START switch.
(9) After the 2-min countdown (left display) is completed, the right display shows the total pressure loss for that
period. A 0.5 in of water loss is acceptable on the self-test.
• If the loss is more than 0.5 in of water, do one or more self-test. If the failed test repeats, check for leak
using the ultrasonic leak detector (part of SST).
2. Press the RESET switch to set the left display reading to 0.0.
01-16–4
1871-1U-06B(01-16).fm 5 ページ 2006年3月15日 水曜日 午前10時48分
id011639800600
1. Remove the air filter.
2. Blow from port A and verify that there is airflow from port B.
• If not as specified, replace the air filter.
3. Blow from port B and verify that there is airflow EVAP SYSTEM LEAK
from port A. ATMOSPHERE
DETECTION PUMP
SIDE
• If not as specified, replace the air filter. SIDE
End Of Sie
WM: CHARCOAL CANISTER
A B
B6U0116W004
01-16–5
1871-1U-06B(01-16).fm 6 ページ 2006年3月15日 水曜日 午前10時48分
1 Evaporative hose
2 Quick release connector 9.0—13.0 2
{92—132, 80—115}
(See 01-14-19 QUICK RELEASE CONNECTOR
REMOVAL/INSTALLATION[L3 WITH TC]) 1
3 Charcoal canister 9.0—13.0
4 Charcoal canister bracket {92—132, 80—115}
9.0—13.0
{92—132, 80—115} N·m {kgf·cm,in·lbf}
acxuuw00000216
Caution
• Do not apply the pressure more than 20
kPa {0.2 kgf/cm2, 2.9 psi} to the charcoal
canister. Doing so will damage the
charcoal canister.
A
3. Verify that there is no air leakage from the case. B
• If not as specified, replace the charcoal C
canister. (See01-16-6 CHARCOAL
CANISTER REMOVAL/INSTALLATION[L3 acxuuw00000179
WITH TC].)
End Of Sie
WM: EVAP SYSTEM LEAK DETECTION PUMP
01-16–6
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
EMISSION SYSTEM [L3 WITH TC]
EVAPORATIVE EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP REMOVAL/INSTALLATION[L3 WITH
TC]
id011639800700
2WD
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table..
1 Connector
2 Evaporative hose 3 01-16
9.0—13.0
3 EVAP system leak detection pump {92—132, 80—115}
9.0—13.0
{92—132, 80—115} 2
N·m {kgf·cm, in·lbf}
acxuuw00000258
AWD
1. Disconnect the negative battery cable.
Note
• Because the AWD EVAP system leak detection pump is installed surrounded by the rear differential, there
is insufficient space for removing the pump from the vehicle. Therefore, it is necessary to remove the
EVAP system leak detection pump and bracket separately from the vehicle.
1 Connector
2 Evaporative hose
3 9.0—13.0
3 EVAP system leak detection pump and bracket
{92—132,
(See 01-16-8 EVAP system leak detection pump 1 80—115}
and bracket removal note)
4 EVAP system leak detection pump
(See 01-16-8 EVAP system leak detection pump
4
and bracket removal note)
2
N·m {kgf·cm, in·lbf}
acxuuw00002564
Note
• Because the AWD EVAP system leak detection pump is installed surrounded by the rear differential, there
is insufficient space for removing the pump from the vehicle. Therefore, it is necessary to remove the
EVAP system leak detection pump and bracket separately from the vehicle.
acxuuw00002565
acxuuw00002567
EVAPORATIVE EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP INSPECTION[L3 WITH TC]
id011639800800
Airflow Inspection
Note
• Perform the following test only when directed.
Resistance Inspection
Note
• Perform the following procedure only when directed.
acxuuw00000042
01–16–8–1
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
EMISSION SYSTEM [L3 WITH TC]
Circuit Open/Short Inspection
1. Disconnect the PCM connector. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH TC].)
2. Inspect the following wiring harnesses for an
open or short circuit (continuity check).
EVAP SYSTEM
LEAD DETECTION PUMP
WIRING HARNESS SIDE CONNECTOR
A
C
B
D
acxuuw00000043
FUSE BOX
(MAIN RELAY)
B
FRONT
A E
D
acxuuw00002334
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000044
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— EVAP system leak detection pump terminal A and main relay terminal E
— EVAP system leak detection pump terminal B and the body ground
— EVAP system leak detection pump terminal C and PCM terminal 1V
— EVAP system leak detection pump terminal D and PCM terminal 1AS
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— EVAP system leak detection pump terminal A and body ground
— EVAP system leak detection pump terminal B and power supply
— EVAP system leak detection pump terminal C and power supply
— EVAP system leak detection pump terminal C and body ground
— EVAP system leak detection pump terminal D and power supply
— EVAP system leak detection pump terminal D and body ground
End Of Sie
01–16–8–2
1871-1U-06B(01-16).fm 9 ページ 2006年3月15日 水曜日 午前10時48分
1 Connector
3
2 Vacuum hose 1
3 Purge solenoid valve 01-16
2
4. Install in the reverse order of removal.
End Of Sie
2
acxuuw00000217
Note
• Perform the following test only when directed.
acxuuw00000046
01-16–9
1871-1U-06B(01-16).fm 10 ページ 2006年3月15日 水曜日 午前10時48分
B A
acxuuw00000047
FUSE BOX
(MAIN RELAY)
B
FRONT
A E
D
acxuuw00002335
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000048
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— Purge solenoid valve terminal A and main relay terminal E
— Purge solenoid valve terminal B and PCM terminal 2AB
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— Purge solenoid valve terminal A and body ground
— Purge solenoid valve terminal B and power supply
— Purge solenoid valve terminal B and body ground
End Of Sie
WM: CHECK VALVE (EMISSION SYSTEM)
01-16–10
1871-1U-06B(01-16).fm 11 ページ 2006年3月15日 水曜日 午前10時48分
R
1
acxuuw00000511
01-16–11
1871-1U-06B(01-16).fm 12 ページ 2006年3月15日 水曜日 午前10時48分
Note
• Perform the following test only when directed.
acxuuw00000049
C
A
E
F D B
acxuuw00000050
01-16–12
1871-1U-06B(01-16).fm 13 ページ 2006年3月15日 水曜日 午前10時48分
E C A
01-16
F D B
acxuuw00000051
FUSE BOX
(MAIN RELAY)
B
FRONT
A E
D
acxuuw00002336
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000052
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— EGR valve terminal A and PCM terminal 2AM
— EGR valve terminal B and PCM terminal 2AR
— EGR valve terminal C or D and main relay terminal E
— EGR valve terminal E and PCM terminal 2AQ
— EGR valve terminal F and PCM terminal 2AN
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— EGR valve terminal A and power supply
— EGR valve terminal A and body ground
— EGR valve terminal B and power supply
— EGR valve terminal B and body ground
— EGR valve terminal C or D and body ground
— EGR valve terminal E and power supply
— EGR valve terminal E and body ground
— EGR valve terminal F and power supply
— EGR valve terminal F and body ground
3. Remove the EGR valve, and inspect for any damage or clogging.
• If there is no damage or clogging, replace the EGR valve. (See 01-16-11 EGR VALVE REMOVAL/
INSTALLATION[L3 WITH TC])
End Of Sie
WM: PCV VALVE
01-16–13
1871-1U-06B(01-16).fm 14 ページ 2006年3月15日 水曜日 午前10時48分
End Of Sie
WM: CATALYTIC CONVERTER
A
acxuuw00001930
Caution
• Perform the following procedures, DTC P0421 is indicated only.
01-16–14
1871-1U-06B(01-17).fm 1 ページ 2006年3月15日 水曜日 午前10時49分
End of Toc
CHARGING SYSTEM LOCATION INDEX[L3 WITH TC]
WM: CHARGING SYSTEM
id011739800100
2
1
acxuuw00002015
1 Battery 2 Generator
(See 01-17-2 BATTERY REMOVAL/ (See 01-17-4 GENERATOR REMOVAL/
INSTALLATION[L3 WITH TC].) INSTALLATION[L3 WITH TC].)
(See 01-17-2 BATTERY INSPECTION[L3 WITH (See 01-17-6 GENERATOR INSPECTION[L3 WITH
TC].) TC].)
(See 01-17-4 BATTERY RECHARGING[L3 WITH (See 01-17-11 GENERATOR DISASSEMBLY/
TC].) ASSEMBLY[L3 WITH TC].)
End Of Sie
WM: BATTERY
01-17–1
1871-1U-06B(01-17).fm 2 ページ 2006年3月15日 水曜日 午前10時49分
7
8.8—12.7
{89.8—129.5,
78.0—112.4}
NOTCH
FRONT
acxuuw00002032
Warning
• Since battery acid is toxic, be careful when handling the battery.
• Since battery acid is highly corrosive, be careful not to allow it to contact clothing or the vehicle.
• In case battery acid contacts skin, eyes, or clothing, flush it immediately with running water.
Especially if the acid gets in the eyes, flush with water for more than 15 min and get prompt
medical attention.
01-17–2
1871-1U-06B(01-17).fm 3 ページ 2006年3月15日 水曜日 午前10時49分
Standard specification
Battery temp. (°C {°F}) Minimum voltage (V)
4 {39} 9.3
10 {50} 9.4
16 {61} 9.5
21 {70} 9.6
Back-up Current
1. Verify that the ignition switch is off (key has been removed) and that all doors are closed.
2. Disconnect the negative battery cable.
3. Connect the tester between the negative battery terminal and negative battery cable, leave the battery
undisturbed for 30 min, and then measure the back-up current.
• If not within the specification, measure the back-up current while removing the fuses one by one from the
inside of the main fuse block and the inside of the fuse block.
Note
• If the battery is not left undisturbed for 30 min, the tester will indicate a high value (approx. 300 mA).
• If the key or any electrical accessory is operated within approx. 30 min after the tester is connected, the
battery must be left undisturbed for approx. 30 min from that point.
Caution
• Operating electrical loads while the back-up current is being measured can damage the tester.
Note
• For vehicles with the immobilizer system, the system periodically shifts synchronization of the security
light flashing. Therefore, 65 mA (0.1 s) current is supplied when the security light is illuminated, and 55
mA (2 s) current is supplied when the security light is not illuminated. In addition, the measuring
instrument, which shows the average value, indicates around 60 mA.
4. Inspect and repair wiring harnesses and connectors of the fuse where the current has decreased.
End Of Sie
01-17–3
1871-1U-06B(01-17).fm 4 ページ 2006年3月15日 水曜日 午前10時49分
Warning
• Keep all flames away from the battery, otherwise evaporated gas from the battery fluid may catch
fire, and cause serious injury.
• Remove the battery filler caps when recharging to prevent battery deformation or damage.
Caution
• Do not quick charge for more than 30 min. It will damage the battery.
Standard voltage
12.4 V or more
End Of Sie
GENERATOR REMOVAL/INSTALLATION[L3 WITH TC]
WM: GENERATOR
id011739800200
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or
serious injury.
• When the battery cables are connected, touching the vehicle body with generator terminal B will
generate sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the negative battery cable before performing the following operation.
Caution
• The generator can be damaged by the heat from the exhaust manifold. Make sure the generator
duct is installed securely.
01-17–4
1871-1U-06B(01-17).fm 5 ページ 2006年3月15日 水曜日 午前10時49分
9.8—14.7 N·m
{100—149 kgf·cm,
87—130 in·lbf}
3
01-17
7.8—10.8 N·m 4
{79.6—110.1 kgf·cm,
69.1—95.5 in·lbf}
2
38—51
{3.9—5.2,
29—37}
A
7.8—10.8 N·m
{79.6—110.1 kgf·cm,
69.1—95.5 in·lbf} B
5
C
1
N·m {kgf·m, ft·lbf}
acxuuw00002016
01-17–5
1871-1U-06B(01-17).fm 6 ページ 2006年3月15日 水曜日 午前10時49分
Caution
• Do not apply direct battery positive voltage to generator terminal D, otherwise it could cause
damage to the internal parts (power transistor) of the generator.
Generator
Voltage
1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is correct. (See 01-10-3 DRIVE BELT INSPECTION[L3 WITH TC].)
3. Turn off all electrical loads.
4. Start the engine.
5. Verify that the generator rotates smoothly without any noise while the engine is running.
• If there is any noise, find the cause and repair or replace the generator.
6. Measure the voltage at each terminal using a
tester.
• If it is not as specified, find the cause and
repair or replace the applicable part.
D P
Generator standard voltage [IG-ON]
Terminal B: B+
Terminal P: Approx. 1 V or less
Terminal D: Approx. 0 V
Current
Note
• Since the charging current decreases rapidly after starting the engine, carry out the following procedure
quickly, and read the maximum current value.
Note
• When the electrical load on the vehicle is low, the specified current cannot be verified although the
generator is normal. In this case, increase the electrical load (Leave the headlights turned on for a while,
then discharge the battery, or use a similar method.) and recheck.
• When the generator itself or the ambient temperature are too high, the specified current also cannot be
verified. In this case, cool down the generator and recheck.
01-17–6
1871-1U-06B(01-17).fm 7 ページ 2006年3月15日 水曜日 午前10時49分
DLC-2
acxuuw00002019
2. Inspect as follows:
Step Inspection Action
1 Measure the generator terminal B voltage when the 15 V or more Go to Step 2.
electrical loads*1 are on and off. 13— 15 V Normal*2
13 V or less Go to Step 3.
2 Monitor the ALTT V PID using the M-MDS, or measure the Yes Go to Step 4.
voltage of PCM terminal 2AJ using a tester. Is the voltage No PCM input error.
between 13 and 15 V ?
3 Monitor the ALTT V PID using the M-MDS, or measure the Yes Go to Step 5.
voltage of PCM terminal 2AJ using a tester. Is the voltage No PCM input error.
between 13 and 15 V ?
4 Monitor the ALTF PID using the M-MDS, or calculate the Yes PCM input error.
duty value of the PCM terminal 2AI using an oscilloscope. No PCM, generator, or
Is the duty value 100 % ? both are not
normal.
A
0V
A
x 100 (%) = DUTY (%)
B
01-17–7
1871-1U-06B(01-17).fm 8 ページ 2006年3月15日 水曜日 午前10時49分
0V
A
x 100 (%) = DUTY (%)
B
*1
: Headlights, blower motor, rear window defroster, and brake lights.
*2 : If the generator field coil duty value does not change when electrical loads (such as headlights, blower motor,
rear window defroster, brake lights) are on or off, inspection with discharged battery is needed.
acxuuw00002021
acxuuw00002022
01-17–8
1871-1U-06B(01-17).fm 9 ページ 2006年3月15日 水曜日 午前10時49分
1 6
2 5
3 4
01-17
acxuuw00002023
acxuuw00002024
acxuuw00002025
Brush
1. Inspect brushes for wear.
• If any brush is worn almost to or beyond the
limit, replace all of the brushes.
MINIMUM
Generator brush length
Standard: 22.5 mm {0.89 in}
Minimum: 5.0 mm {0.20 in}
STANDARD
acxuuw00002026
01-17–9
1871-1U-06B(01-17).fm 10 ページ 2006年3月15日 水曜日 午前10時49分
acxuuw00002027
acxuuw00002028
Bearing
1. Inspect for abnormal noise, looseness, and
sticking.
• Replace the bearing if necessary.
End Of Sie
acxuuw00002029
01-17–10
1871-1U-06B(01-17).fm 11 ページ 2006年3月15日 水曜日 午前10時49分
Caution
• Melt the solder quickly, otherwise the diodes (rectifier) and regulator will be damaged by excessive
heat.
4
1
2
3.5—5.3 6
{35—55, 31—47}
6.9—10.8
11 {70—110, 61—96}
9
5
2.9—4.9
{30—50,
26—43}
98—137 N·m
3
{10.0—13.9 kgf·m, 7
2.9—4.9
72—101 ft·lbf} 2.9—4.9
{30—50,
26—43} {30—50,
26—43}
10
1.5—2.5 2.9—4.9
{15—25, 13—22} {30—50,
26—43}
8
1.5—2.5
{15—25, 13—22}
End Of Sie
01-17–11
1871-1U-06B(01-18).fm 1 ページ 2006年3月15日 水曜日 午前10時51分
End of Toc
IGNITION SYSTEM LOCATION INDEX[L3 WITH TC]
WM: IGNITION SYSTEM
id011839800100
acxuuw00002034
End Of Sie
WM: IGNITION COIL
01-18–1
1871-1U-06B(01-18).fm 2 ページ 2006年3月15日 水曜日 午前10時51分
End Of Sie
WM: SPARK PLUG A B C
acxuuw00001990
01-18–2
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
IGNITION SYSTEM [L3 WITH TC]
SPARK PLUG REMOVAL/INSTALLATION[L3 WITH TC]
id011839800400
Caution
• If a spark plug that is not as specified is installed, engine performance will be deteriorated. Install
only the specified spark plug when replacing.
Tightening torque
10— 14 N·m {1.1— 1.4 kgf·m, 8.0— 10 ft·lbf}
End Of Sie
SPARK PLUG INSPECTION[L3 WITH TC]
id011839800500
Specification
Caution
• To avoid possible damage to the tip, do not adjust the plug gap.
• To prevent damaging the tip, use a wire type plug gap gauge when inspecting the plug gap.
1. Measure the spark plug gap using a wire type plug gap gauge.
• If not within the specification, replace the spark plug.
Cleaning
Caution
• Carbon may adhere to the tip of the spark plug during vehicle delivery or repeated short distance
driving during the winter time. If there is any malfunction such as rough idling or start difficulty
due to carbon adhesion causing plug fouling, burn off the carbon by performing no-load racing of
the engine.
• When performing the no-load racing, apply the side brake and foot brake, move the selector lever
to P position to prevent an accident and serious injury.
• To avoid possible damage to the spark plug tip, do not use a wire brush for cleaning.
Note
• To avoid possible damage to the tip, use gasoline to clean the spark plugs after removing dirt.
• If the accelerator pedal is depressed continuously for a specified time, the engine speed may decrease to
the idle speed. This is due to the fuel cut control operation, which prevents overheating, and it does not
indicate a malfunction.
• Do not perform no-load racing at high engine speed continuously for 10 s or more.
1. If there is carbon adhering to the spark plug, perform no-load racing at 4,000 rpm for 2 min, 2 times.
acxuuw00002036
Resistance Inspection
1. Measure the resistance of the spark plug using a
tester as shown in the figure.
• If not within the specification, replace the
spark plug.
End Of Sie
acxuuw00002037
01-18–4
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
STARTING SYSTEM [L3 WITH TC]
01-19 STARTING SYSTEM [L3 WITH TC]
STARTING SYSTEM LOCATION INDEX On-vehicle Inspection . . . . . . . . . . . . . . 01-19–4
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-19–1 No-load Test . . . . . . . . . . . . . . . . . . . . . 01-19–4
STARTER REMOVAL/INSTALLATION Magnetic Switch
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-19–2 Operation Inspection . . . . . . . . . . . . . . 01-19–4
Heater Pipe Removal Note . . . . . . . . . 01-19–3
Pinion Gap Inspection . . . . . . . . . . . . 01-19-4–1 01-19
Starter Removal Note . . . . . . . . . . . . . 01-19–3
Starter Inner Parts Inspection . . . . . . 01-19-4–1
Starter Installation Note . . . . . . . . . . . . 01-19–3
STARTER DISASSEMBLY/ASSEMBLY
STARTER INSPECTION [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-19–7
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-19–4
End of Toc
STARTING SYSTEM LOCATION INDEX[L3 WITH TC]
WM: STARTING SYSTEM
id011939800100
1
acxuuw00002038
1 Starter
(See 01-19-2 STARTER REMOVAL/
INSTALLATION[L3 WITH TC].)
(See 01-19-4 STARTER INSPECTION[L3 WITH
TC].)
(See 01-19-7 STARTER DISASSEMBLY/
ASSEMBLY[L3 WITH TC].)
End Of Sie
WM: STARTER
Warning
• Remove and install all parts when the engine is cold, otherwise they can cause severe burns or
serious injury.
• When the battery cables are connected, touching the vehicle body with starter terminal B will
generate sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the negative battery cable before performing the following operation.
1. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].)
2. Remove the charge air cooler duct, air cleaner and fresh air duct component, and air hose. (See 01-13-5
INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
3. Remove the under cover.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
TURBOCHARGER
9.8—11.7 N·m
{100—119 kgf·cm,
86.8—103.5 in·lbf}
3 A
16.3—23.5
{1.7—2.3, 12.1—17.3}
38—51 {3.9—5.2, 29—37}
5
38—51 {3.9—5.2, 29—37}
2
16.3—23.5
{1.7—2.3, 12.1—17.3}
1
7.8—10.8 N·m
{79.6—110.1 kgf·cm, 69.1—95.5 in·lbf}
N·m {kgf·m, ft·lbf}
acxuuw00002039
.
INSULATOR
STARTER
acxaaw00000762
INSULATOR STARTER
ATTACHMENT AREA
acxaaw00000763
INSULATOR STARTER
acxaaw00000764
No-load Test
1. Verify that the battery is fully charged.
2. Connect the starter, battery, and a tester as
shown in the figure.
IG SW TESTER
3. Operate the starter and verify that it rotates
A
smoothly.
• If the starter does not rotate smoothly, inspect B
Note
• Depending on the battery charge condition, the starter motor pinion may rotate while in an extended state.
This is due to current flowing to the starter motor through the pull-in coil to turn the starter motor, and does
not indicate an abnormality.
acxuuw00002041
01-19–4
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
STARTING SYSTEM [L3 WITH TC]
Return test
01-19-4 STARTING SYSTEM [L3 WITH TC]
acxuuw00002042
Caution
• Applying power for more than 10 s can
damage the starter. Do not apply power
for more than 10 s.
acxuuw00002041
PINION GAP
acxuuw00002043
acxuuw00002044
01-19-4–1
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
STARTING SYSTEM [L3 WITH TC]
01-19-4–2
1871-1U-06B(01-19).fm 5 ページ 2006年3月15日 水曜日 午前10時51分
01-19
acxuuw00002045
acxuuw00002046
acxuuw00002047
acxuuw00002048
01-19–5
1871-1U-06B(01-19).fm 6 ページ 2006年3月15日 水曜日 午前10時51分
acxuuw00002049
acxuuw00002050
acxuuw00002051
acxuuw00002052
01-19–6
1871-1U-06B(01-19).fm 7 ページ 2006年3月15日 水曜日 午前10時51分
acxuuw00002053
3. Measure the brush spring force using a spring
balance.
• If not within the minimum specification,
replace the brush and brush holder
component.
9.8—11.8
1 {100—120,
87—104}
4.1—7.6
{42—77,
37—66}
6
4.4—7.1
8 {45—72,
40—62}
11
2.4—4.4
{25—44,
22—38}
10 2
3
9
4
acxuuw00002055
.
01-19–7
1871-1U-06B(01-20).fm 1 ページ 2006年3月15日 水曜日 午前10時52分
End of Toc
CRUISE CONTROL SWITCH INSPECTION[L3 WITH TC]
WM: CRUISE CONTROL SWITCH
id012039800100 01-20
1. Disconnect the negative battery cable.
2. Remove the driver-side air bag module. (See08-10-6 DRIVER-SIDE AIR BAG MODULE REMOVAL/
INSTALLATION.)
3. Disconnect the cruise control switch connector.
4. Inspect for resistance and continuity between the
cruise control switch terminals using an
ohmmeter.
D
• If not as specified, replace the cruise control CRUISE
switch. CONTROL MAIN E
SWITCH
B
: Continuity : Resistance : Diode
A B C D E F G H
Terminal CANCEL SWITCH
Switch position
B C D E SET/COAST
Cruise control main SWITCH
switch held at on RESUME/ACCEL
CANCEL switch R1 SWITCH
held at on
SET/COAST C
R2
switch held at on
RESUME/ACCEL
R3
switch held at on acxuuw00000280
Neutral
R1: 117.6—122.4 ohms R2: 666.4—693.6 ohms
R3: 2,156—2,244 ohms
acxuuw00000281
End Of Sie
01-20–1
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
CONTROL SYSTEM [L3 WITH TC]
01-40 CONTROL SYSTEM [L3 WITH TC]
CONTROL SYSTEM COMPONENT Voltage Inspection . . . . . . . . . . . . . . . . . 01-40–32
LOCATION INDEX[L3 WITH TC] . . . . . 01-40–2 Circuit Open/Short Inspection . . . . . . . . 01-40–33
CONTROL SYSTEM DIAGRAM ACCELERATOR PEDAL POSITION
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-40–3 (APP) SENSOR INSPECTION
CONTROL SYSTEM WIRING DIAGRAM [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-40–33
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-40–4 Voltage Inspection . . . . . . . . . . . . . . . . . 01-40–33 01-40
PCM REMOVAL/INSTALLATION Circuit Open/Short Inspection . . . . . . . . 01-40–34
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-40–6 FUEL PRESSURE SENSOR
REMOVAL/INSTALLATION
PCM Connector Connection Note . . . . 01-40–6 [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-40–35
PCM INSPECTION[L3 WITH TC] . . . . . 01-40-6–1 FUEL PRESSURE SENSOR
Without Using the M-MDS . . . . . . . . . 01-40-6–1 INSPECTION[L3 WITH TC]. . . . . . . . . . 01-40–35
Inspection Using An Oscilloscope Circuit Open/Short Inspection . . . . . . . . 01-40–36
(Reference) . . . . . . . . . . . . . . . . . . . . 01-40–13 HEATED OXYGEN SENSOR (HO2S)
Using the M-MDS. . . . . . . . . . . . . . . . . 01-40–16 REMOVAL/INSTALLATION
PCM CONFIGURATION [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-40–37
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-40–21 HO2S Removal Note. . . . . . . . . . . . . . . 01-40–37
POWER STEERING PRESSURE (PSP) HEATED OXYGEN SENSOR (HO2S)
SWITCH INSPECTION INSPECTION[L3 WITH TC] . . . . . . . . . . 01-40–37
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-40–22 Front HO2S Current Inspection. . . . . . . 01-40–37
Continuity Inspection . . . . . . . . . . . . . . 01-40–22 Front HO2S Heater
Circuit Open/Short Inspection . . . . . . . 01-40–22 Resistance Inspection . . . . . . . . . . . . . 01-40–38
VARIABLE SWIRL SHUTTER VALVE Front HO2S Circuit
SWITCH INSPECTION Open/Short Inspection (Sensor) . . . . 01-40–38
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-40–23 Rear HO2S Voltage Inspection . . . . . . . 01-40–39
Voltage Inspection . . . . . . . . . . . . . . . . 01-40–23 Rear HO2S Circuit
Circuit Open/Short Inspection . . . . . . . 01-40–24 Open/Short Inspection (Sensor) . . . . . 01-40–40
ENGINE COOLANT TEMPERATURE Rear HO2S Heater
(ECT) SENSOR Resistance Inspection . . . . . . . . . . . . . 01-40–41
REMOVAL/INSTALLATION Rear HO2S Circuit Open/Short
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-40–24 Inspection (Heater). . . . . . . . . . . . . . . 01-40–41
ENGINE COOLANT TEMPERATURE CRANKSHAFT POSITION (CKP)
(ECT) SENSOR INSPECTION SENSOR REMOVAL/INSTALLATION
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-40–25 [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-40–42
ECT Sensor Resistance Inspection . . . 01-40–25 Removal . . . . . . . . . . . . . . . . . . . . . . . . 01-40–42
Circuit Open/Short Inspection . . . . . . . 01-40–25 Installation . . . . . . . . . . . . . . . . . . . . . . . 01-40–42
MASS AIR FLOW (MAF) SENSOR CRANKSHAFT POSITION (CKP)
INSPECTION[L3 WITH TC] . . . . . . . . . 01-40–26 SENSOR INSPECTION
Visual Inspection . . . . . . . . . . . . . . . . . 01-40–26 [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-40–43
Voltage Inspection . . . . . . . . . . . . . . . . 01-40–26 Air Gap Inspection. . . . . . . . . . . . . . . . . 01-40–43
Circuit Open/Short Inspection . . . . . . . 01-40–26 Visual Inspection . . . . . . . . . . . . . . . . . . 01-40–43
INTAKE AIR TEMPERATURE (IAT) Voltage Inspection . . . . . . . . . . . . . . . . . 01-40–43
SENSOR INSPECTION Circuit Open/Short Inspection . . . . . . . . 01-40–44
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-40–27 CAMSHAFT POSITION (CMP) SENSOR
Resistance Inspection . . . . . . . . . . . . . 01-40–27 REMOVAL/INSTALLATION
Circuit Open/Short Inspection . . . . . . . 01-40–28 [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-40–45
MANIFOLD ABSOLUTE PRESSURE CAMSHAFT POSITION (CMP) SENSOR
(MAP) SENSOR/BOOST AIR INSPECTION[L3 WITH TC] . . . . . . . . . . 01-40–45
TEMPERATURE SENSOR Visual Inspection . . . . . . . . . . . . . . . . . . 01-40–45
REMOVAL/INSTALLATION Voltage Inspection . . . . . . . . . . . . . . . . . 01-40–45
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-40–29 Circuit Open/Short Inspection . . . . . . . . 01-40–46
MANIFOLD ABSOLUTE PRESSURE KNOCK SENSOR (KS)
(MAP) SENSOR INSPECTION REMOVAL/INSTALLATION
[L3 WITH TC] . . . . . . . . . . . . . . . . . . . . 01-40–29 [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-40–47
Circuit Open/Short Inspection . . . . . . . 01-40–30 KNOCK SENSOR (KS) INSPECTION
BOOST AIR TEMPERATURE SENSOR [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-40–47
INSPECTION[L3 WITH TC]. . . . . . . . . . 01-40–31 Resistance Inspection . . . . . . . . . . . . . . 01-40–47
Resistance Inspection . . . . . . . . . . . . . 01-40–31 Circuit Open/Short Inspection . . . . . . . . 01-40–48
Circuit Open/Short Inspection . . . . . . . 01-40–31 BAROMETRIC PRESSURE (BARO)
THROTTLE POSITION (TP) SENSOR SENSOR INSPECTION
INSPECTION[L3 WITH TC]. . . . . . . . . . 01-40–32 [L3 WITH TC] . . . . . . . . . . . . . . . . . . . . . 01-40–48
End of Toc
Revised 12/2006 (Ref. No. R215/06) 01-40–1
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
CONTROL SYSTEM [L3 WITH TC]
CONTROL SYSTEM COMPONENT LOCATION INDEX[L3 WITH TC]
WM: ENGINE CONTROL SYSTEM
id014039800200
WU-TWC 7
9
5
6
12
1
2
10
11
8 13
4
acxuuw00000130
01-40–2
1871-1U-06B(01-40).fm 3 ページ 2006年3月15日 水曜日 午前10時53分
End Of Sie
CONTROL SYSTEM DIAGRAM[L3 WITH TC]
id014039800300
VARIABLE SWIRL
SHUTTER VALVE SWITCH
PCM
CMP SENSOR
CKP SENSOR
: TO PCM
acxuuw00000131
End Of Sie
01-40–3
1871-1U-06B(01-40).fm 4 ページ 2006年3月15日 水曜日 午前10時53分
c 2BG
FUEL INJECTOR
1AY
2BB NO.1
b
a 1BE FUEL INJECTOR
NO.4
2AZ
1BA
2BH
FUEL INJECTOR
1AZ NO.3
2BD
FUEL INJECTOR
NO.2
2BC
1AR 2BF
IAT SENSOR FUEL INJECTOR RELAY
1M 2BE
MAF 1AK
1AW
SENSOR
1P
2C HO2S HEATER (FRONT)
1Q
HO2S HEATER (REAR)
1AV 2D
APP 1Y
SENSOR 1AE FAN CONTROL MODULE NO.1
1U
1AC
COOLING FAN
RELAY NO.1
1AJ
PCM
1AO b
2P
FUEL PRESSURE SENSOR
2R 1R FAN CONTROL MODULE NO.2
2I
COOLING FAN
2AY RELAY NO.2
ECT SENSOR 1K
2AH
A/C RELAY b
1I
2AV
FUEL PUMP SPEED CONTROL RELAY
MAP 1AA
2AG
SENSOR
2N
BOOST AIR TEMPERATURE
FUEL PUMP RESISTOR
SENSOR 2AU
1BC
HO2S (REAR)
2Q FUEL PUMP RELAY
1H
2M b
1AT
2AD
MAIN RELAY
HO2S
(FRONT) 2AC
STARTER RELAY c
2Z 1B
IGNITION
2Y
SWITCH
DRIVE-BY-WIRE-RELAY
2X
1BF
CKP SENSOR
2W 1AX
BATTERY
CMP SENSOR 2S
f a
d e
acxuuw00002265
01-40–4
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
CONTROL SYSTEM [L3 WITH TC]
d e f
EGR VALVE
2AQ
2AM
2V
KS 01-40
2U 2AR
2AN
2AK
2AP
EVAP SYSTEM LEAK
DETECTION PUMP
TP SENSOR
2AL 1V
b
2AO 1AS
2E
REFRIGERANT PRESSURE SWITCH (HIGH, LOW)
1AU 2B
THROTTLE
REFRIGERANT PRESSURE SWITCH (MIDDLE) 2A
ACTUATOR
1J
2F
PSP SWITCH SPILL VALVE CONTROL
2T
2G
SOLENOID VALVE
2H
1BB
1AQ
1BD
1BH
2AI GENERATOR
acxuuw00002266
End Of Sie
WM: PCM
01-40–5
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
CONTROL SYSTEM [L3 WITH TC]
PCM REMOVAL/INSTALLATION[L3 WITH TC]
id014039802400
Note
• For PCM replacement, set up the M-MDS and perform the PCM configuration. (See 01-40-21 PCM
CONFIGURATION[L3 WITH TC].)
VIEW FROM A
A
7.8—10.8
{80—110,
69—95} FRONT
3
1
7.8—10.8
{80—110, 69—95}
acxuuw00001858
Caution
• If the PCM connector is inserted at an
angle and the lever is moved, the
connector could be damaged. Verify that
the PCM connector is inserted straight.
End Of Sie
acxaaw00000768
LEVER
towards the wiring harness side as shown in the PCM
WIRING
figure.
HARNESS
2. Insert the PCM connector straight until it contacts
the PCM and verify that the lever reverts upward
naturally.
01-40
PCM CONNECTOR
acxuuw00002577
acxuuw00002578
01-40-6–2
1871-1U-06B(01-40).fm 7 ページ 2006年3月15日 水曜日 午前10時53分
PCM
WIRING HARNESS SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C 01-40
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000125
Voltage
Terminal Signal Connected to Test condition Inspection item
(V)
1A — — — — —
Ignition switch off after 10 s Below 1.0 • Starter relay
1B Starter relay control Starter relay • Related wiring
Ignition switch to the ON position Below 1.0 harness
1C — — — — —
1D — — — — —
1E — — — — —
1F — — — — —
1G — — — — —
Ignition switch to the ON position
B+ • Fuel pump relay
after 10 s
1H Fuel pump control Fuel pump relay • Related wiring
Cranking B+
harness
Idle Below 1.0
A/C operating Below 1.0 • A/C relay
1I A/C A/C relay Idle A/C not • Related wiring
B+ harness
operating
Refrigerant
pressure is
more than the
specification. Below 1.0
(Refrigerant
pressure switch • Refrigerant pressure
Refrigerant Refrigerant (middle) is on.) switch
1J pressure switch pressure switch A/C ON
Refrigerant • Related wiring
(middle) (middle)
pressure is less harness
than the
specification. B+
(Refrigerant
pressure switch
(middle) is off.)
1K — — — — —
1L — — — — —
IAT 20 °C
Ignition switch {68 °F} 2.4—2.6 • MAF/IAT sensor
1M IAT MAF/IAT sensor to the ON • Related wiring
position IAT 30 °C harness
1.7—1.9
{86 °F}
1N — — — — —
1O — — — — —
• Related wiring
1P MAF sensor ground MAF/IAT sensor Under any condition Below 1.0
harness
• Related wiring
Approx.
1Q APP sensor voltage APP sensor Ignition switch to the ON position harness
5.0
• APP sensor
01-40–7
1871-1U-06B(01-40).fm 8 ページ 2006年3月15日 水曜日 午前10時53分
01-40–8
1871-1U-06B(01-40).fm 9 ページ 2006年3月15日 水曜日 午前10時53分
01-40–9
1871-1U-06B(01-40).fm 10 ページ 2006年3月15日 水曜日 午前10時53分
01-40–10
1871-1U-06B(01-40).fm 11 ページ 2006年3月15日 水曜日 午前10時53分
01-40–11
1871-1U-06B(01-40).fm 12 ページ 2006年3月15日 水曜日 午前10時53分
01-40–12
1871-1U-06B(01-40).fm 13 ページ 2006年3月15日 水曜日 午前10時53分
acxuuw00000274
0V
acxuuw00000275
acxuuw00000127
01-40–13
1871-1U-06B(01-40).fm 14 ページ 2006年3月15日 水曜日 午前10時53分
ov
acxuuw00000128
acxuuw00002325
0V
ampjjw00001527
OCV signal
PCM terminals
• 2AF (+)— body ground (–)
Oscilloscope setting
• 2.5 V/DIV (Y), 1 ms/DIV (X), DC range
Vehicle condition
• Idle after warm up (no load, P/S off, A/C off)
ov
acxuuw00000129
01-40–14
1871-1U-06B(01-40).fm 15 ページ 2006年3月15日 水曜日 午前10時53分
ampjjw00001528
0V
ampjjw00001529
ampjjw00000781
acxuuw00002326
01-40–15
1871-1U-06B(01-40).fm 16 ページ 2006年3月15日 水曜日 午前10時53分
acxuuw00000277
Note
• PIDs for the following parts are not available on this model. Perform the specific inspections for the
following parts:
— CMP sensor (See01-40-45 CAMSHAFT POSITION (CMP) SENSOR INSPECTION[L3 WITH TC].)
— Main relay
Note
• The PID/DATA MONITOR function monitors
the calculated value of the input/output
signals in the PCM. Therefore, an output
DLC-2
device malfunction is not directly indicated
acxuuw00000278
as a malfunction of the monitored value for
the output device. If a monitored value of an
output device is out of specification, inspect the monitored value of the input device related to the output
control.
• For input/output signals except those of the monitoring items, use a voltmeter to measure the PCM
terminal voltage.
• The simulation items that are used in the ENGINE CONTROL SYSTEM OPERATION INSPECTION are
as follows.
— ACCS, ALTF, ARPMDES, FAN_DUTY, EVAPCP, FP, FUELPW, GENVDSD, HTR11, HTR12, IMRC,
INJ_1, INJ_2, INJ_3, INJ_4, SEGRP, test, VT DUTY1, WGC
01-40–16
1871-1U-06B(01-40).fm 17 ページ 2006年3月15日 水曜日 午前10時53分
01-40–17
1871-1U-06B(01-40).fm 18 ページ 2006年3月15日 水曜日 午前10時53分
01-40–18
1871-1U-06B(01-40).fm 19 ページ 2006年3月15日 水曜日 午前10時53分
01-40–19
1871-1U-06B(01-40).fm 20 ページ 2006年3月15日 水曜日 午前10時53分
01-40–20
1871-1U-06B(01-40).fm 21 ページ 2006年3月15日 水曜日 午前10時53分
End Of Sie
PCM CONFIGURATION[L3 WITH TC]
id014039802600
1. Connect the M-MDS to DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the M-MDS.
• When using the IDS (notebook PC)
1. Select the “Module Programming”.
• When using the PDS (pocket PC)
1. Select “Programming”.
2. Select “Module Programming”.
3. Then, select the “Programmable Module
Installation”, “PCM” from the screen menu.
Note DLC-2
• If the PCM is replaced with a new one, the acxuuw00000279
PCM stores DTC P0602, illuminates the MIL
even though no malfunction is detected. When the configuration is completed, DTC P0602 is cleared.
4. Retrieve DTC’s using the M-MDS, then verify that DTC are present.
• If a DTC is present, perform the applicable DTC inspection.
End Of Sie
01-40–21
1871-1U-06B(01-40).fm 22 ページ 2006年3月15日 水曜日 午前10時53分
id014039803100
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
Continuity Inspection
1. Inspect the following if the power steering is inoperative (See06-14-3 POWER STEERING FLUID
INSPECTION.):
• Power steering fluid level
• Power steering fluid leakage
• Power steering fluid pressure
2. Disconnect the PSP switch connector.
3. Start the engine.
4. Inspect for continuity between the PSP switch terminal and ground using a tester.
• If not as specified, replace the PSP switch. (See06-14-21 POWER STEERING OIL PUMP REMOVAL/
INSTALLATION.)
• If the PSP switch is normal, but PID value is out of specification, perform the “Circuit Open/Short
Inspection”.
Specification
: Continuity
Condition Terminal GND
Steering wheel in straight
ahead position
While turning steering
wheel
acxuuw00000116
PSP SWITCH
WIRING HARNESS SIDE CONNECTOR
acxuuw00000117
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000118
1. Disconnect the PCM connector. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH TC].)
2. Inspect the following harnesses for an open or short circuit. (Continuity check)
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— PSP switch terminal and PCM terminal 2T
Short circuit
• If there is no continuity, there is a short circuit. Repair or replace the wiring harness.
— PSP switch terminal and body ground
01-40–22
1871-1U-06B(01-40).fm 23 ページ 2006年3月15日 水曜日 午前10時53分
id014039803000
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See00-00-3 HOW TO USE THIS MANUAL.)
Voltage Inspection
1. Turn the ignition switch to the ON position (Engine off). 01-40
2. Verify that the PCM terminal 2AE voltage is as VARIABLE SWIRL SHUTTER VALVE
shown in the following table when the variable ACTUATOR ROD
swirl shutter valve actuator rod is depressed and OPEN POSITION
released by hand. (RELEASED)
CLOSED POSITION
(DEPRESSED)
acxuuw00000113
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000114
01-40–23
1871-1U-06B(01-40).fm 24 ページ 2006年3月15日 水曜日 午前10時53分
A B
acxuuw00000115
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000114
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— Variable swirl shutter valve switch terminal A and PCM terminal 2AE
— Variable swirl shutter valve switch terminal B and body ground.
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— Variable swirl shutter valve switch terminal A and power supply
— Variable swirl shutter valve switch terminal A and body ground
— Variable swirl shutter valve switch terminal B and power supply
End Of Sie
ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION[L3 WITH TC]
WM: TEMPERATURE SENSOR
id014039801900
Warning
• A hot engine can cause severe burns. Turn off the engine and wait until it is cool before removing
the ECT sensor.
01-40–24
1871-1U-06B(01-40).fm 25 ページ 2006年3月15日 水曜日 午前10時53分
Tightening torque
ECT SENSOR
10— 14 N·m {102— 142 kgf·cm, 89— 123
in·lbf}
acxuuw00000091
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
ECT SENSOR
WIRING HARNESS SIDE CONNECTOR
B A
acxuuw00000092
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000093
01-40–25
1871-1U-06B(01-40).fm 26 ページ 2006年3月15日 水曜日 午前10時53分
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— ECT sensor terminal A and power supply
— ECT sensor terminal A and body ground
— ECT sensor terminal B and power supply
End Of Sie
MASS AIR FLOW (MAF) SENSOR INSPECTION[L3 WITH TC]
WM: MASS AIR FLOW SENSOR
id014039800700
Visual Inspection
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
1. Visually inspect for the following on the MAF sensor. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/
INSTALLATION[L3 WITH TC].)
• Damage
• Cracks
• Bent terminals
• Terminal rust
— If any of the above are found, replace the MAF/IAT sensor.
— If the monitor item status/specification (reference) is not within the specification even though there is no
malfunction, perform the "Circuit Open/Short Inspection".
Voltage Inspection
1. Remove the MAF/IAT sensor without disconnect the MAF/IAT sensor connector.
2. Turn the ignition switch to the ON position.
3. As the air gradually approaches the MAF detection part of the MAF/IAT sensor, verify that the voltage at PCM
terminal 1AK (M-MDS PID: MAF) varies.
• If it cannot be verified even though the related harnesses have no malfunction, replace the MAF/IAT sensor.
MAF/IAT SENSOR
WIRING HARNESS SIDE CONNECTOR
E D C B A
acxuuw00000076
FUSE BOX
(MAIN RELAY)
B
FRONT
A E
D
acxuuw00000538
01-40–26
1871-1U-06B(01-40).fm 27 ページ 2006年3月15日 水曜日 午前10時53分
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
01-40
acxuuw00000078
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— MAF/IAT sensor terminal A and main relay terminal E
— MAF/IAT sensor terminal B and PCM terminal 1P
— MAF/IAT sensor terminal C and PCM terminal 1AK
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— MAF/IAT sensor terminal A and body ground
— MAF/IAT sensor terminal B and power supply
— MAF/IAT sensor terminal C and power supply
— MAF/IAT sensor terminal C and body ground
End Of Sie
INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION[L3 WITH TC]
WM: INTAKE AIR TEMPERATURE SENSOR
id014039802200
Resistance Inspection
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
01-40–27
1871-1U-06B(01-40).fm 28 ページ 2006年3月15日 水曜日 午前10時53分
MAF/IAT SENSOR
WIRING HARNESS SIDE CONNECTOR
E D C B A
acxuuw00000097
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000098
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— MAF/IAT sensor terminal D and PCM terminal 1M
— MAF/IAT sensor terminal E and PCM terminal 1AR
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— MAF/IAT sensor terminal E and power supply
— MAF/IAT sensor terminal D and power supply
— MAF/IAT sensor terminal D and body ground
End Of Sie
WM: MANIFOLD ABSOLUTE PRESSURE SENSOR
01-40–28
1871-1U-06B(01-40).fm 29 ページ 2006年3月15日 水曜日 午前10時53分
Tightening torque
5.0— 7.0 N·m {51— 71 kgf·cm, 45— 61 in·lbf}
End Of Sie
MAP/BOOST AIR
TEMPERATURE
SENSOR
acxuuw00000082
Note
• Perform the following inspection only when directed.
• The following vacuum values are indicated by relative pressure from the MAP sensor.
01-40–29
1871-1U-06B(01-40).fm 30 ページ 2006年3月15日 水曜日 午前10時53分
MAP/BOOST AIR
TEMPERATURE SENSOR
WIRING HARNESS SIDE CONNECTOR
D C B A
acxuuw00000080
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000081
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— MAP/boost air temperature sensor terminal A and PCM terminal 2AV
— MAP/boost air temperature sensor terminal C and PCM terminal 2AU
— MAP/boost air temperature sensor terminal D and PCM terminal 2AG
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— MAP/boost air temperature sensor terminal A and power supply.
— MAP/boost air temperature sensor terminal C and body ground.
— MAP/boost air temperature sensor terminal D and power supply.
— MAP/boost air temperature sensor terminal D and body ground
End Of Sie
WM: INTAKE AIR TEMPERATURE SENSOR
01-40–30
1871-1U-06B(01-40).fm 31 ページ 2006年3月15日 水曜日 午前10時53分
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
D C B A
acxuuw00000094
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000095
1. Disconnect the PCM connector. (See01-40-6 PCM REMOVAL/INSTALLATION[L3 WITH TC].)
2. Inspect the following wiring harnesses for an open or short circuit. (Continuity check)
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— MAP/boost air temperature sensor terminal A and PCM terminal 2AV
— MAP/boost air temperature sensor terminal B and PCM terminal 2N
— MAP/boost air temperature sensor terminal C and PCM terminal 2AU
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— MAP/boost air temperature sensor terminal A and power supply
— MAP/boost air temperature sensor terminal B and power supply
— MAP/boost air temperature sensor terminal B and body ground
— MAP/boost air temperature sensor terminal C and body ground
01-40–31
1871-1U-06B(01-40).fm 32 ページ 2006年3月15日 水曜日 午前10時53分
id014039802700
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
Voltage Inspection
1. Verify that no DTC related to the APP sensor has been detected.
• If any DTCs related to the APP sensor have been detected, perform the DTC inspection.
(See01-02-13 DTC TABLE[L3 WITH TC].)
2. Start the engine and warm it up (ECT: more than 80°C {176 °F}).
3. Turn the ignition switch to the ON position (Engine off).
4. Verify that the PCM terminal 2AK and 2AL change smoothly while the throttle valve is gradually opened.
• If as verified, go to next step.
• If not as verified, perform the “Circuit Open/Short Inspection”.
— If there is no open or short circuit, replace the throttle body.
5. Verify that the PCM terminal 2AK and 2AL voltages are as shown in the following table.
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000108
• If the voltage is not according to the following table, perform the “Circuit Open/Short Inspection”.
— If there is no open or short circuit, replace the throttle body.
TP sensor output voltage TP SENSOR CHARACTERISTICS (REFERENCE)
PCM terminal PCM terminal
Condition 2AK 2AL
(TP sensor No.1) (TP sensor No.2)
HIGH TP SENSOR No.1
APP is released 0.4— 0.6 V 4.4— 4.6 V
APP is depressed 4.7— 4.9 V 0.1— 0.3 V
LOW
THROTTLE
SMALL LARGE
OPENING ANGLE
acxuuw00000109
01-40–32
1871-1U-06B(01-40).fm 33 ページ 2006年3月15日 水曜日 午前10時53分
TP SENSOR
WIRING HARNESS SIDE CONNECTOR
F E D C B A
01-40
acxuuw00000110
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000108
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— Throttle body terminal A and PCM terminal 2AK
— Throttle body terminal B and PCM terminal 2AO
— Throttle body terminal C and PCM terminal 2AL
— Throttle body terminal D and PCM terminal 2AP
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— Throttle body terminal A and power supply
— Throttle body terminal A and body ground
— Throttle body terminal B and body ground
— Throttle body terminal C and power supply
— Throttle body terminal C and body ground
— Throttle body terminal D and power supply
End Of Sie
ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION[L3 WITH TC]
WM: ACCELERATOR PEDAL POSITION SENSOR
id014039803200
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
Voltage Inspection
1. Turn the ignition switch to the ON position (Engine off).
2. Verify that the PCM terminal 1Y and 1AC change smoothly while throttle valve is gradually opened.
• If as verified, go to next step.
• If not as verified, perform the “Circuit Open/Short Inspection”.
— If there is no open or short circuit, replace the throttle body. (See01-13-5 INTAKE AIR SYSTEM
REMOVAL/INSTALLATION[L3 WITH TC].)
01-40–33
1871-1U-06B(01-40).fm 34 ページ 2006年3月15日 水曜日 午前10時53分
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000119
• If the voltage is not according to the following table, perform the “Circuit Open/Short Inspection”.
— If there is no open or short circuit, replace accelerator pedal. (See01-13-17 ACCELERATOR PEDAL
REMOVAL/INSTALLATION[L3 WITH TC].)
LOW
THROTTLE
SMALL LARGE
OPENING ANGLE
acxuuw00000120
APP SENSOR
WIRING HARNESS SIDE CONNECTOR
F E D C B A
acxuuw00001926
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000119
01-40–34
1871-1U-06B(01-40).fm 35 ページ 2006年3月15日 水曜日 午前10時53分
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— APP sensor terminal A and PCM terminal 1AJ
— APP sensor terminal B and PCM terminal 1AV
— APP sensor terminal C and PCM terminal 1AC 01-40
— APP sensor terminal D and PCM terminal 1Q
— APP sensor terminal E and PCM terminal 1U
— APP sensor terminal F and PCM terminal 1Y
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— APP sensor terminal A and body ground
— APP sensor terminal B and power supply
— APP sensor terminal C and power supply
— APP sensor terminal C and body ground
— APP sensor terminal D and body ground
— APP sensor terminal E and power supply
— APP sensor terminal F and power supply
— APP sensor terminal F and body ground
End Of Sie
FUEL PRESSURE SENSOR REMOVAL/INSTALLATION[L3 WITH TC]
WM: FUEL PRESSURE SENSOR
id014039801200
Note
• If the fuel pressure sensor is removed, do not reuse the fuel pressure sensor and the fuel delivery pipe.
When you replace the fuel pressure sensor, replace a new fuel delivery pipe with a new fuel pressure
sensor. (See 01-14-23 FUEL INJECTOR REMOVAL/INSTALLATION[L3 WITH TC])
End Of Sie
FUEL PRESSURE SENSOR INSPECTION[L3 WITH TC]
id014039801300
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
5. After connecting the spill valve control solenoid valve connector, clear the DTC.
01-40–35
1871-1U-06B(01-40).fm 36 ページ 2006年3月15日 水曜日 午前10時53分
C B A
acxuuw00000085
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000086
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— Fuel pressure sensor terminal A and PCM terminal 2P
— Fuel pressure sensor terminal B and PCM terminal 2R
— Fuel pressure sensor terminal C and PCM terminal 2I
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— Fuel pressure sensor terminal A and power supply.
— Fuel pressure sensor terminal B and power supply.
— Fuel pressure sensor terminal B and body ground.
— Fuel pressure sensor terminal C and body ground
End Of Sie
WM: HEATED OXYGEN SENSOR
01-40–36
1871-1U-06B(01-40).fm 37 ページ 2006年3月15日 水曜日 午前10時53分
Warning
• A hot engine and exhaust system can cause severe burns. Turn off the engine and wait until they
are cool before removing the exhaust system.
1 Connector SST
2 29—49
Front HO2S {3.0—4.9, 22—36}
2
(See01-40-37 HO2S Removal Note.)
3 Rear HO2S 1
(See01-40-37 HO2S Removal Note.) SST
3 29—49
{3.0—4.9, 22—36}
ampjjw00001053
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
01-40–37
1871-1U-06B(01-40).fm 38 ページ 2006年3月15日 水曜日 午前10時53分
VSS
0 KPH
3,000 RPM
2,000 RPM
RPM
1,000 RPM
0 RPM
0.25 mA
0.25 mA OR MORE
O2S11
0 mA
acxuuw00000099
• If not within the specification, inspect the HO2S for an open or short circuit. (See01-40-38 Front HO2S
Circuit Open/Short Inspection (Sensor).) Then if there is no malfunction in the wiring harness, replace the
front HO2S.
acxuuw00000100
1C 1A 2C 2A
1D 1B 2D 2B
acxuuw00000101
01-40–38
1871-1U-06B(01-40).fm 39 ページ 2006年3月15日 水曜日 午前10時53分
FUSE BOX
(MAIN RELAY)
B
FRONT
A E
D
01-40
acxuuw00000538
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000103
Open circuit
• If there is no continuity in the following wiring harnesses, there is an open circuit. Repair or replace the wiring
harness.
— Front HO2S terminal 1A and PCM terminal 2AD
— Front HO2S terminal 1B and PCM terminal 2AC
— Front HO2S terminal 1C and PCM terminal 2Z
— Front HO2S terminal 2A and PCM terminal 2M
— Front HO2S terminal 2B and main relay terminal E
— Front HO2S terminal 2C and PCM terminal 2Y
— Front HO2S terminal 2D and PCM terminal 2C
Short circuit
• If there is continuity in the following wiring harnesses, there is a short circuit. Repair or replace the wiring
harness.
— Front HO2S terminal 1A and body ground
— Front HO2S terminal 1A and power supply
— Front HO2S terminal 1B and body ground
— Front HO2S terminal 1B and power supply
— Front HO2S terminal 1C and body ground
— Front HO2S terminal 1C and power supply
— Front HO2S terminal 2A and power supply
— Front HO2S terminal 2B and body ground
— Front HO2S terminal 2C and body ground
— Front HO2S terminal 2C and power supply
— Front HO2S terminal 2D and body ground
— Front HO2S terminal 2D and power supply
01-40–39
1871-1U-06B(01-40).fm 40 ページ 2006年3月15日 水曜日 午前10時53分
VSS
0 KPH
3,000 RPM
1,000 RPM
0 RPM
1V
O2S12 0.5V
0.3V OR LESS
0V
acxuuw00000104
• If not within the specification, inspect the HO2S for an open or short circuit. (See01-40-40 Rear HO2S
Circuit Open/Short Inspection (Sensor).) Then if there is no malfunction in the wiring harness, replace the
rear HO2S.
A C
B D
acxuuw00000105
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000103
01-40–40
1871-1U-06B(01-40).fm 41 ページ 2006年3月15日 水曜日 午前10時53分
acxuuw00000106
A C
B D
acxuuw00000107
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000103
1. Disconnect the PCM connector.
2. Disconnect the rear HO2S connector.
3. Inspect the following wiring harnesses for an open or short circuit. (Continuity check)
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— Rear HO2S terminal C and ignition switch
— Rear HO2S terminal D and PCM terminal 2D
Short circuit
• If there is no continuity, there is a short circuit. Repair or replace the wiring harness.
Rear
— Rear HO2S terminal A and body ground
— Rear HO2S terminal B and power supply
— Rear HO2S terminal B and body ground
01-40–41
1871-1U-06B(01-40).fm 42 ページ 2006年3月15日 水曜日 午前10時53分
id014039800600
Removal
1. Disconnect the negative battery cable.
2. Remove the charge air cooler duct. (See01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH
TC].)
3. Remove the under cover.
4. Remove the splash shield (RH).
5. Disconnect the CKP sensor connector.
6. Remove the installation bolts to remove the CKP sensor.
Installation
Caution
• When foreign material, such as an iron chips, gets on the CKP sensor, it can cause abnormal
output from the sensor because of flux turbulence and adversely affect engine control. Be sure
there is no foreign material on the CKP sensor when replacing.
1. Perform the following procedure so that piston No.1 is at the top dead center.
(1) Rotate the crankshaft in the direction of the
engine rotation and remove the cylinder block
lower blind plug when the No. 1 cylinder is at
the point prior to top dead center (TDC) of
compression, then install the SST.
(2) Rotate the crankshaft in the direction of the
engine rotation so that the No.1 piston is at
TDC of the compression stroke. (Until the
crank weight contacts SST and stops.)
303-507
acxuuw00001899
Caution
• If the line is not accurately drawn, CENTER LINE
ignition timing, fuel injection and other OF SENSOR
engine control systems will be adversely
effected. Draw the straight line carefully
using a straight edge.
5. Remove the SST then install the cylinder block lower blind plug.
Tightening torque
18— 22 N·m {1.9— 2.2 kgf·m, 14— 16 ft·lbf}
End Of Sie
01-40–42
1871-1U-06B(01-40).fm 43 ページ 2006年3月15日 水曜日 午前10時53分
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
Air gap
0.5— 1.5 mm {0.02— 0.05 in}
CKP SENSOR
acxuuw00000070
Visual Inspection
1. Disconnect the negative battery cable.
2. Remove the CKP sensor. (See01-40-42 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/
INSTALLATION[L3 WITH TC].)
3. Verify that there are no metal shavings on the sensor.
• If the monitor item condition/specification (reference) is without the specification even though there is no
malfunction, carry out the “Circuit Open/Short Inspection”.
Voltage Inspection
1. Idle the engine.
Caution
• Water penetrating the connector will cause sensor malfunction. To prevent this, be careful not to
damage the wiring harnesses or the waterproof connector so as to cause water penetration.
Voltage
Terminal Voltage (V) Condition
A Below 1.0 Under any condition acxuuw00000071
4.8 or more High output*
B
0.8 or less Low output*
C B+ Under any condition
*
: Output voltage varies with crankshaft rotation.
01-40–43
1871-1U-06B(01-40).fm 44 ページ 2006年3月15日 水曜日 午前10時53分
CKP SENSOR
WIRING HARNESS SIDE CONNECTOR
C B A
acxuuw00000071
FUSE BOX
(MAIN RELAY)
B
FRONT
A E
D
acxuuw00000538
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000073
1. Inspect the following wiring harnesses for an open or short circuit. (Continuity check)
Open circuit
• If there is no continuity, the circuit is open. Repair or replace the wiring harness.
— CKP sensor terminal A and PCM terminal 2P
— CKP sensor terminal B and PCM terminal 2W
— CKP sensor terminal C and main relay terminal E
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
— CKP sensor terminal A and power supply
— CKP sensor terminal B and power supply
— CKP sensor terminal B and body ground
— CKP sensor terminal C and body ground
End Of Sie
WM: CAMSHAFT POSITION SENSOR
01-40–44
1871-1U-06B(01-40).fm 45 ページ 2006年3月15日 水曜日 午前10時53分
Caution
• When replacing the CMP sensor, make sure there is no foreign material on it such as metal
shavings. If it is installed with foreign material, the sensor output signal will malfunction resulting
from fluctuation in magnetic flux and cause a deterioration in engine control.
Tightening torque
5.5— 7.5 N·m {57— 76 kgf·cm, 49— 66 in·lbf}
CMP SENSOR
End Of Sie
acxuuw00000090
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
Visual Inspection
1. Disconnect the negative battery cable.
2. Remove the CMP sensor. (See01-40-45 CAMSHAFT POSITION (CMP) SENSOR REMOVAL/
INSTALLATION[L3 WITH TC].)
3. Verify that there are no metal shavings on the sensor.
• If the monitor item condition/specification (reference) is not within the specification even though there is no
malfunction, carry out the “Circuit Open/Short Inspection”.
Voltage Inspection
1. Idle the engine.
Caution
• Water penetrating the connector will cause sensor malfunction. To prevent this, be careful not to
damage the wiring harnesses or the waterproof connector so as to cause water penetration.
01-40–45
1871-1U-06B(01-40).fm 46 ページ 2006年3月15日 水曜日 午前10時53分
Voltage
Terminal Voltage (V) Condition
acxuuw00000087
A B+ Under any condition
B Below 1.0 Under any condition
4.8 or more High output*
C
0.8 or less Low output*
* : Output voltage varies with camshaft rotation.
CMP SENSOR
WIRING HARNESS SIDE CONNECTOR
C B A
acxuuw00000087
FUSE BOX
(MAIN RELAY)
B
FRONT
A E
D
acxuuw00000538
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000089
1. Inspect the following wiring harnesses for an open or short circuit. (Continuity check)
01-40–46
1871-1U-06B(01-40).fm 47 ページ 2006年3月15日 水曜日 午前10時53分
Short circuit
• If there is continuity, the circuit is shorted. Repair or replace the wiring harness. 01-40
— CMP sensor terminal A and body ground
— CMP sensor terminal B and power supply
— CMP sensor terminal C and body ground
— CMP sensor terminal C and power supply
End Of Sie
KNOCK SENSOR (KS) REMOVAL/INSTALLATION[L3 WITH TC]
WM: KNOCK SENSOR
id014039802900
Caution
• Be careful not to impact the sensor.
• Verify that there is no debris between the sensor and the cylinder block before installing.
Tightening torque
16— 24 N·m {1.7— 2.4 kgf·m, 12— 17 ft·lbf}
End Of Sie
KS
VIEW A
acxuuw00001859
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-3 HOW TO USE THIS MANUAL.)
Resistance Inspection
1. Turn the ignition switch to the LOCK position.
2. Disconnect the KS connector.
3. Measure the resistance between KS terminals A and B using a tester.
• If not as specified, replace the KS. (See01-40-47 KNOCK SENSOR (KS) REMOVAL/INSTALLATION[L3
WITH TC].)
• If the KS is normal, but the PID value is out of specification, perform the “Circuit Open/Short Inspection”.
Specification
Approx. 4.87 megohms
01-40–47
1871-1U-06B(01-40).fm 48 ページ 2006年3月15日 水曜日 午前10時53分
KS
WIRING HARNESS SIDE CONNECTOR
A B
acxuuw00000111
PCM
WIRING HARNESS-SIDE CONNECTOR
2BE 2BA 2AW 2AS 2AO 2AK 2AG 2AC 2Y 2U 2Q 2M 2I 2E 2A 1BE 1BA 1AW 1AS 1AO 1AK 1AG 1AC 1Y 1U 1Q 1M 1I 1E 1A
2BF 2BB 2AX 2AT 2AP 2AL 2AH 2AD 2Z 2V 2R 2N 2J 2F 2B 1BF 1BB 1AX 1AT 1AP 1AL 1AH 1AD 1Z 1V 1R 1N 1J 1F 1B
2BG 2BC 2AY 2AU 2AQ 2AM 2AI 2AE 2AA 2W 2S 2O 2K 2G 2C 1BG 1BC 1AY 1AU 1AQ 1AM 1AI 1AE 1AA 1W 1S 1O 1K 1G 1C
2BH 2BD 2AZ 2AV 2AR 2AN 2AJ 2AF 2AB 2X 2T 2P 2L 2H 2D 1BH 1BD 1AZ 1AV 1AR 1AN 1AJ 1AF 1AB 1X 1T 1P 1L 1H 1D
acxuuw00000112
Open circuit
• If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
— KS terminal A and PCM terminal 2U
— KS terminal B and PCM terminal 2V
Short circuit
• If there is continuity, there is a short circuit. Repair or replace the wiring harness.
— KS terminal A and power supply
— KS terminal A and body ground
— KS terminal B and power supply
— KS terminal B and body ground
End Of Sie
BAROMETRIC PRESSURE (BARO) SENSOR INSPECTION[L3 WITH TC]
WM: FUEL PRESSURE SENSOR
id014039801100
Note
• Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See00-00-3 HOW TO USE THIS MANUAL.)
DLC-2
acxuuw00000083
01-40–48
1871-1U-06B(01-50).fm 1 ページ 2006年3月15日 水曜日 午前10時55分
End of Toc
ENGINE TECHNICAL DATA[L3 WITH TC]
WM: ENGINE
id015039800100 01-50
Item Specification
IN: 0.22—0.28 mm {0.0087—0.011 in}
Standard valve clearance [Engine cold]
EX: 0.27—0.33 mm {0.011—0.012 in}
Standard:1,280 kPa {13.1 kgf/cm2, 185.65 psi}[250rpm]
Compression Minimum:896 kPa {9.14 kgf/cm2, 129.96 psi}[250rpm]
Maximum difference between cylinders:196.1 kPa {2.0 kgf/cm2, 28.5
psi}
Standard
144.7—145.3 mm {5.697—5.720 in}
Cylinder head bolt length
Maximum:
146 mm {5.74 in}
Front oil seal press-in amount 0—0.5 mm {0—0.019 in}
OCV resistance 6.9—7.9 ohms [20°C {68°F}]
Ignition timing Approx. BTDC 10°
No load: 650—750 rpm
Idle speed (P, N position) Electrical load on*1: 650—750 rpm
P/S operation: 650—750 rpm
A/C operation: 650—750 rpm
No load: 575—675 rpm
Idle speed (D position) Electrical load on*1: 600—700 rpm
P/S operation: 650—750 rpm
A/C operation: 650—750 rpm
HC concentration: Within the regulation
Idle mixture
CO concentration: Within the regulation
Oil pressure (reference value) [oil temperature: 100 °C
{212 °F}] 297—551 kPa {3.03—5.61 kgf/cm2, 43.1—79.9 psi} [3,000 rpm]
Oil replacement: 5.3 L {5.6 US qt, 4.7 Imp qt}
Engine oil capacity (approx. quantity) Oil and oil filter replacement: 5.7 L {6.0 US qt, 5.0 Imp qt}
Total (dry engine): 6.4 L {6.8 US qt, 5.6 Imp qt}
Engine coolant capacity (approx. quantity) 9.0 L {9.5 US qt, 7.9 Imp qt}
Cooling fan motor No.1, No.2 standard current 17.5—22.5 A
Cooling system cap valve opening pressure 112.8—142.2 kPa {1.15—1.45 kgf/cm2, 16.4—20.6 psi}
Thermostat initial-opening temperature 80—84 °C {176—183 °F}
Thermostat full-open temperature 97 °C {207 °F}
Thermostat full-open lift More than 8.0 mm {0.31 in}
Fuel line pressure 410—490 kPa {4.2—4.9 kgf/cm2, 60—71 psi}
Fuel pump hold pressure More than 230 kPa {2.3 kgf/cm2, 33 psi}
Fuel injector resistance 1.0—1.2 ohms [20 °C {68 °F}]
Battery electrolyte specific gravity [20 °C {68 °F}] 1.22—1.29
55D23L (48): 180 A
Battery load test current
80D26L (55): 195 A
Vehicles with immobilizer system: 55—65 mA
Battery back-up current
Vehicles without immobilizer system: 60 mA or less
55D23L (48): 4.5—5.5 A
Battery slow charge current
80D26L (55): 5.5—6.5 A
55D23L (48): 30 A
Battery quick charge current [30 min]
80D26L (55): 35 A
Terminal B: B+
Generator standard voltage [IG-ON] Terminal P: Approx. 1 V or less
Terminal D: Approx. 0 V
01-50–1
1871-1U-06B(01-50).fm 2 ページ 2006年3月15日 水曜日 午前10時55分
CYLINDER No.
CRANKSHAFT
ENGINE
PULLEY
Firing order 1
*1 : When the following electrical loads are on: Headlights, rear defroster, cooling fan No.1, cooling fan No.2, and
the blower motor (2-step or more.)
(ILSAC) (ILSAC)
API SL or ILSAC
Engine oil viscosity 5W-30
End Of Sie
01-50–2
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
SERVICE TOOLS [L3 WITH TC]
01-60 SERVICE TOOLS [L3 WITH TC]
ENGINE SST[L3 WITH TC]. . . . . . . . . . . 01-60–1
End of Toc
ENGINE SST[L3 WITH TC]
WM: ENGINE
id016039800100
1: Mazda SST number 01-60
2: Global SST number
Example
1:49 UN01 052
2:310–D005
Spring lock
coupler tool
(green)
Handle Installer —
End Of Sie
SUSPENSION 02SECTION
Toc of SCT
ON-BOARD DIAGNOSTIC . . . . 02-02 WHEEL AND TIRES. . . . . . . . . 02-12
02-02
SYMPTOM FRONT SUSPENSION . . . . . . . 02-13
TROUBLESHOOTING . . . . . . 02-03 REAR SUSPENSION . . . . . . . . 02-14
GENERAL PROCEDURES . . . . 02-10 TECHNICAL DATA . . . . . . . . . . 02-50
WHEEL ALIGNMENT . . . . . . . . 02-11 SERVICE TOOLS . . . . . . . . . . . 02-60
Toc of SCT
02-02 ON-BOARD DIAGNOSTIC
TIRE PRESSURE MONITORING Freeze Frame PID Data Access
SYSTEM (TPMS) WIRING DIAGRAM . . 02-02–2 Procedure. . . . . . . . . . . . . . . . . . . . . . 02-02–4
With Advanced Keyless System . . . . . . 02-02–2 DTC Table . . . . . . . . . . . . . . . . . . . . . . 02-02–5
With Keyless Entry System . . . . . . . . . . 02-02–2 PID/DATA Monitor Table . . . . . . . . . . . . 02-02–5
TIRE PRESSURE MONITORING Active Command Modes Table. . . . . . . 02-02–6
SYSTEM (TPMS) ON-BOARD MALFUNCTIONING WHEEL UNIT
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 02-02–3 IDENTIFICATION . . . . . . . . . . . . . . . . . 02-02–7
On-Board Diagnostic (OBD) DTC B2143 . . . . . . . . . . . . . . . . . . . . . . . 02-02–8
Test Description . . . . . . . . . . . . . . . . . 02-02–3 DTC B2868, B2869, B2870, B2871. . . . . 02-02–8
Reading DTCs Procedure . . . . . . . . . . . 02-02–3 DTC U0127 . . . . . . . . . . . . . . . . . . . . . . . 02-02–9
Clearing DTCs Procedures . . . . . . . . . . 02-02–3 With Advanced Keyless System. . . . . . 02-02–9
PID/Data Monitor and Record With Keyless Entry System . . . . . . . . . 02-02–10
Procedure . . . . . . . . . . . . . . . . . . . . . . 02-02–4 DTC U2616, U2617, U2618, U2619. . . . . 02-02–11
Active Command Modes Procedure . . . 02-02–4
End of Toc
WM: TIRE PRESSURE MONITORING SYSTEM
02-02–1
1871-1U-06B(02-02).fm 2 ページ 2006年3月15日 水曜日 午前10時56分
ON-BOARD DIAGNOSTIC
TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING DIAGRAM
id020200800100
With Advanced Keyless System
WHEEL UNIT
KEYLESS
RF SIGNAL
RECEIVE
INSTRUMENT
CLUSTER
PCM
ANTENNA
KEYLESS CM CAN_H
2R
CAN_L
2T
A 3A 3Q 2N
C 3C
CAN
DRIVER
E 2B
2A
DLC-2
acxuuw00002405
WHEEL UNIT
RF SIGNAL
KEYLESS
INSTRUMENT
RECEIVER
CLUSTER
PCM
ANTENNA
CAN_H
2R
A
CAN_L
2T
B
CAN
D 2N DRIVER
2A
DLC-2
acxuuw00002406
End Of Sie
02-02–2
1871-1U-06B(02-02).fm 3 ページ 2006年3月15日 水曜日 午前10時56分
ON-BOARD DIAGNOSTIC
TIRE PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD DIAGNOSIS
id020200800200
On-Board Diagnostic (OBD) Test Description
• The OBD test inspects the integrity and function of the TPMS and outputs the results when requested by the
specific tests.
• On-board diagnostic test also:
— Provides a quick inspection of the TPMS usually performed at the start of each diagnostic procedure.
— Provides verification after repairs to ensure that no other faults occurred during service.
• The OBD test is divided into 3 tests:
— Read/clear diagnostic results, PID monitor and active command mode.
02-02
Read/clear diagnostic results
• This function allows you to read or clear DTCs in the instrument cluster memory.
02-02–3
1871-1U-06B(02-02).fm 4 ページ 2006年3月15日 水曜日 午前10時56分
ON-BOARD DIAGNOSTIC
PID/Data Monitor and Record Procedure
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (notebook PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Module”.
4. Select “IC”.
• When using the PDS (pocket PC)
1. Select “Module Tests”.
2. Select “IC”.
DLC-2
3. Select “DataLogger”.
acxuuw00001190
3. Select the applicable PID from the PID table.
4. Verify the PID data according to the directions on
the screen.
Note
• The PID/Data monitor function is used for monitoring the calculated value. Therefore, if the monitored
value of the output parts is not within the specification, inspection of the monitored value of input parts
corresponding to applicable output part control is necessary. In addition, because the system does not
display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output
part individually using a active command modes function.
02-02–4
1871-1U-06B(02-02).fm 5 ページ 2006年3月15日 水曜日 午前10時56分
ON-BOARD DIAGNOSTIC
DTC Table
DTC
Description Page
M-MDS
B1342 Instrument cluster internal malfunction (See 09-02E-5 DTC B1342[INSTRUMENT
CLUSTER].)
B2143 ID registration failure (See 02-02-8 DTC B2143.)
B2477 Instrument cluster configuration not performed (See 09-02E-5 DTC B2477[INSTRUMENT
CLUSTER].)
B2868 Wheel unit No.1 internal malfunction (See 02-02-8 DTC B2868, B2869, B2870,
B2871.) 02-02
B2869 Wheel unit No.2 internal malfunction (See 02-02-8 DTC B2868, B2869, B2870,
B2871.)
B2870 Wheel unit No.3 internal malfunction (See 02-02-8 DTC B2868, B2869, B2870,
B2871.)
B2871 Wheel unit No.4 internal malfunction (See 02-02-8 DTC B2868, B2869, B2870,
B2871.)
U0127 Communication failure between instrument (See 02-02-9 DTC U0127.)
cluster and keyless receiver
U2616 Wheel unit No.1 (No response) (See 02-02-11 DTC U2616, U2617, U2618,
U2619.)
U2617 Wheel unit No.2 (No response) (See 02-02-11 DTC U2616, U2617, U2618,
U2619.)
U2618 Wheel unit No.3 (No response) (See 02-02-11 DTC U2616, U2617, U2618,
U2619.)
U2619 Wheel unit No.4 (No response) (See 02-02-11 DTC U2616, U2617, U2618,
U2619.)
02-02–5
1871-1U-06B(02-02).fm 6 ページ 2006年3月15日 水曜日 午前10時56分
ON-BOARD DIAGNOSTIC
PID Name Unit/
Condition/Specification Action
(Definition) Condition
FFD2_WU1_T
FFD2_WU2_T
FFD2_WU3_T Indicates the internal tire air
°C/°F Adjust tire pressure.
FFD2_WU4_T temperature. (Freeze frame PID data 2)
(Internal tire air temperature value
(freeze frame PID data 2))
FFD1_MLG
Indicates the mileage. (Freeze frame
(Wheel unit mileage value (freeze m/mi (ft) Adjust tire pressure.
PID data 1)
frame PID data 1))
FFD2_MLG
Indicates the mileage. (Freeze frame
(Wheel unit mileage value (freeze m/mi (ft) Adjust tire pressure.
PID data 2)
frame PID data 2))
FFD1_SPD
Indicates the speed. (Freeze frame PID
(Wheel unit speed value (freeze KPH/MPH Adjust tire pressure.
data 1)
frame PID data 1))
FFD2_SPD
Indicates the speed. (Freeze frame PID
(Wheel unit speed value (freeze KPH/MPH Adjust tire pressure.
data 2)
frame PID data 2))
IC_DTC_CNT
– Indicates number of DTC Perform the DTC inspection.
(Number of continuous DTCs)
ID_LAST*
Indicates the last ID that is transmitted • Replace the wheel unit.
(Last received tire transmitter ID –
from the wheel unit. • Perform the configuration.
code value)
ID_WU1*
ID_WU2* • Replace the wheel unit.
Indicates the registered ID that is
ID_WU3* – • Perform the wheel unit ID
transmitted from the wheel unit.
ID_WU4* registration.
(Registered wheel unit ID code)
WU1_P*
WU2_P*
Indicates the tire pressure. (See 02-50- • Adjust tire pressure.
WU3_P* Pa/psi
1 SUSPENSION TECHNICAL DATA.) • Replace the wheel unit.
WU4_P*
(Tire pressure value)
WU1_T*
WU2_T*
Indicates the internal tire air
WU3_T* °C/°F Replace the wheel unit.
temperature.
WU4_T*
(Internal tire air temperature value)
* : Data transmission from the wheel unit occurs when the vehicle speed is 25 km/h {15.5 mph} or more. Due to
this, the current air pressure and temperature data can only be displayed after the vehicle is driven at 25 km/h
{15.5 mph} or more. Also, the ID_LAST, and tire pressure and internal tire air temperature data are erased
when the instrument cluster connector and the battery terminal are disconnected. If the instrument cluster is
replaced or the battery terminals are disconnected, drive the vehicle at 25 km/h {15.5 mph} or more and
display the tire pressure PID after the data transmission.
End Of Sie
02-02–6
1871-1U-06B(02-02).fm 7 ページ 2006年3月15日 水曜日 午前10時56分
ON-BOARD DIAGNOSTIC
MALFUNCTIONING WHEEL UNIT IDENTIFICATION
id020200800300
Note
• The tire pressure monitoring system (TPMS) does not identify the location of the malfunctioning wheel
unit on the vehicle (RF, LF, LR, RR). The TPMS identifies each wheel unit as No.1, No.2, No.3 and No.4. In
order to identify the location of the wheel unit, perform the following procedure.
FR: WU2_P
FL: WU1_P
RL: WU4_P
RR: WU3_P
acxuuw00001191
02-02–7
1871-1U-06B(02-02).fm 8 ページ 2006年3月15日 水曜日 午前10時56分
ON-BOARD DIAGNOSTIC
DTC B2143
id020200800400
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY THE PROGRAMMED ID Yes Register the wheel unit ID, then go to the next step.
• Turn the ignition switch off. (See 02-12-4 WHEEL UNIT ID REGISTRATION.)
• Connect the M-MDS to the DLC-2. No Go to the next step.
• Select the following PIDs using the M-MDS:
— ID_WU1
— ID_WU2
— ID_WU3
— ID_WU4
• Turn the ignition switch to the ON position.
• Is the same code in the output ID?
2 VERIFY TROUBLESHOOTING COMPLETED Yes • Repeat the inspection from Step 1.
• Clear the DTC from the memory. If the malfunction recurs, replace the instrument cluster
(See 02-02-3 TIRE PRESSURE and/or wheel unit.
MONITORING SYSTEM (TPMS) ON- (See 09-22-2 INSTRUMENT CLUSTER REMOVAL/
BOARD DIAGNOSIS.) INSTALLATION.)
• Drive the vehicle at a speed of 25 km/h {15.5 (See 02-12-4 WHEEL UNIT REMOVAL/
mph} or more for 10 min or more. INSTALLATION.)
• Is the same DTC present? No Go to the next step.
3 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. (See 02-02-3 TIRE
• Are there any other DTCs present? PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD
DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
DTC B2868, B2869, B2870, B2871
id020200800500
Diagnostic procedure
STEP INSPECTION ACTION
1 IDENTIFY MALFUNCTIONING WHEEL UNIT • Identify the malfunctioning wheel unit.
• (See 02-02-7 MALFUNCTIONING WHEEL UNIT • Replace and register the wheel unit. (See 02-12-4
IDENTIFICATION.) WHEEL UNIT ID REGISTRATION.)
• Go to the next step.
2 VERIFY TROUBLESHOOTING COMPLETED Yes Go to Step 1.
• Clear the DTC from the memory. No Go to the next step.
(See 02-02-3 TIRE PRESSURE
MONITORING SYSTEM (TPMS) ON-
BOARD DIAGNOSIS.)
• Drive the vehicle at a speed of 25 km/h {15.5
mph} or more for 10 min or more.
• Is the same DTC present?
3 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. (See 02-02-3 TIRE
• Are there any other DTCs present? PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD
DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
02-02–8
1871-1U-06B(02-02).fm 9 ページ 2006年3月15日 水曜日 午前10時56分
ON-BOARD DIAGNOSTIC
DTC U0127
id020200800600
DTC U0127 • Communication failure between instrument cluster and keyless receiver
DETECTION
• The instrument cluster cannot receive signal from the keyless CM or keyless receiver.
CONDITION
With advanced keyless system
• Open or short circuit in the wiring harness between the keyless CM terminal 3Q and the instrument
cluster terminal 2N.
• Keyless control module malfunction.
• Instrument cluster malfunction.
POSSIBLE • Poor connection at connectors (female terminal) 02-02
CAUSE With keyless entry system
• Open or short circuit in the wiring harness between the keyless receiver terminal D and the instrument
cluster terminal 2N.
• Keyless receiver malfunction.
• Instrument cluster malfunction.
• Poor connection at connectors (female terminal)
02-02–9
1871-1U-06B(02-02).fm 10 ページ 2006年3月15日 水曜日 午前10時56分
ON-BOARD DIAGNOSTIC
With Keyless Entry System
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT WHEEL UNIT SIGNAL FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace the wiring harness for an open circuit
• Turn the ignition switch off. between keyless receiver terminal D and instrument cluster
• Disconnect keyless receiver and instrument terminal 2N, then go to Step 4.
cluster connectors.
• Inspect for continuity between keyless
receiver terminal D (harness-side) and
instrument cluster terminal 2V (harness-
side).
• Is there continuity?
2 INSPECT WHEEL UNIT SIGNAL FOR SHORT Yes Repair or replace the wiring harness for a short to power
TO POWER between keyless receiver terminal D and instrument cluster
• Turn the ignition switch off. terminal 2N, then go to Step 4.
• Disconnect keyless receiver and instrument No Go to the next step.
cluster connectors.
• Measure the voltage between keyless
receiver terminal D (harness-side) and
ground.
• Is there B+?
3 INSPECT WHEEL UNIT SIGNAL FOR SHORT Yes Repair or replace the wiring harness for a short to ground
TO GROUND between keyless receiver terminal D and instrument cluster
• Turn the ignition switch off. terminal 2N, then go to the next step.
• Disconnect keyless receiver and instrument No Replace keyless receiver, then go to the next step. (See 09-
cluster connectors. 14-36 KEYLESS RECEIVER REMOVAL/INSTALLATION.)
• Inspect for continuity between keyless
receiver terminal D (harness-side) and
ground.
• Is there continuity?
4 VERIFY TROUBLESHOOTING COMPLETED Yes • If the malfunction recurs, replace the instrument cluster.
• Clear the DTC from the memory. (See 09-22-2 INSTRUMENT CLUSTER REMOVAL/
(See 02-02-3 TIRE PRESSURE INSTALLATION.)
MONITORING SYSTEM (TPMS) ON- • Configure the instrument cluster. (See 09-22-3
BOARD DIAGNOSIS.) INSTRUMENT CLUSTER CONFIGURATION.)
• Turn the ignition switch to the ON position • Register the wheel unit ID. (See 02-12-4 WHEEL UNIT
and wait for 30 s. ID REGISTRATION.)
• Is the same DTC present? • Go to the next step.
No Go to the next step.
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. (See 02-02-3 TIRE
• Drive the vehicle at a speed of 25 km/h {15.5 PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD
mph} or more for 10 min or more. DIAGNOSIS.)
• Are there any other DTCs present? No DTC troubleshooting completed.
End Of Sie
02-02–10
1871-1U-06B(02-02).fm 11 ページ 2006年3月15日 水曜日 午前10時56分
ON-BOARD DIAGNOSTIC
DTC U2616, U2617, U2618, U2619
id020200800700
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY WHEEL UNIT IS INSTALLED TO Yes Go to the Step 3.
EACH WHEEL No • Install the wheel unit. (See 02-12-4 WHEEL UNIT
• Are all four wheels equipped with a wheel REMOVAL/INSTALLATION.)
unit? • Register the wheel unit ID. (See 02-12-4 WHEEL UNIT
ID REGISTRATION.)
• Go to the next step.
2 INSPECT FOR DTCs Yes Go to the next step.
• Drive the vehicle at a speed of 25 km/h {15.5 No With advanced keyless system: go to the Step 4.
mph} or more for 10 min or more. With keyless entry system: go to the Step 5.
• Is the same DTC present?
3 IDENTIFY MALFUNCTIONING WHEEL UNIT • Identify the malfunctioning wheel unit.
• (See 02-02-7 MALFUNCTIONING WHEEL UNIT • Replace the wheel unit. (See 02-12-4 WHEEL UNIT
IDENTIFICATION.) REMOVAL/INSTALLATION.)
• Register the wheel unit ID. (See 02-12-4 WHEEL UNIT
ID REGISTRATION.)
• Go to the Step 5.
4 INSPECT FOR KEYLESS CM MALFUNCTION Yes Go to the applicable DTC inspection. (See 09-02C-3 DTC
• Turn the ignition switch off. TABLE[IMMOBILIZER SYSTEM (KEYLESS ENTRY
• Using the M-MDS, perform the DTC SYSTEM)].)
inspection for the keyless CM. No Go to the next step.
• Is any DTCs present?
5 VERIFY TROUBLESHOOTING COMPLETED Yes • If the malfunction recurs, replace the instrument cluster.
• Clear the DTC from the memory. (See 09-22-2 INSTRUMENT CLUSTER REMOVAL/
(See 02-02-3 TIRE PRESSURE INSTALLATION.)
MONITORING SYSTEM (TPMS) ON- • Configure the instrument cluster. (See 09-22-3
BOARD DIAGNOSIS.) INSTRUMENT CLUSTER CONFIGURATION.)
• Drive the vehicle at a speed of 25 km/h {15.5 • Register the wheel unit ID. (See 02-12-4 WHEEL UNIT
mph} or more for 10 min or more. ID REGISTRATION.)
• Is the same DTC present? • Go to the next step.
No Go to the next step.
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection. (See 02-02-3 TIRE
• Are there any other DTCs present? PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD
DIAGNOSIS.)
No DTC troubleshooting completed.
Note
• If the installed wheel unit ID number is known, verification of whether the instrument cluster is receiving
data from the wheel unit can be easily confirmed using the following procedure:
1. Drive the vehicle at 25 km/h {15.5 mph} or more, and send data from the wheel unit.
2. Select [ID_LAST] from the PID items, and monitor the data.
3. Verification that the instrument cluster is receiving data is possible if the monitored ID number
matches the installed wheel unit ID number.
• If the wheel unit has been newly replaced, the TPMS warning light may flashes before the ID registration
is complete, and DTC U2616, U2617, U2618 and U2619 may be stored in the memory. In this case, re-
implement the wheel unit ID registration, and after confirming that the TPMS warning light is no longer
flashing, erase the DTC. If the TPMS warning light does not go out, a malfunction on any one of the wheel
units may have occurred and the ID registration will not have been correctly performed. Repeat the
diagnostic procedure from Step 1 and perform and inspection.
End Of Sie
02-02–11
1871-1U-06B(02-03).fm 1 ページ 2006年3月15日 水曜日 午前10時57分
SYMPTOM TROUBLESHOOTING
02-03 SYMPTOM TROUBLESHOOTING
TIRE PRESSURE No.1 TPMS WARNING LIGHT
MONITORING SYSTEM (TPMS) ILLUMINATES CONTINUOUSLY . . . . . 02-03–4
WIRING DIAGRAM . . . . . . . . . . . . . . . . 02-03–2 No.2 TPMS WARNING LIGHT
With Advanced Keyless System. . . . . . 02-03–2 (LOW PRESSURE WARNING)
With Keyless Entry System . . . . . . . . . 02-03–2 ILLUMINATES AFTER ENGINE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . 02-03–2 START AND TURNS OFF AFTER
PRECAUTION . . . . . . . . . . . . . . . . . . . . . 02-03–3 DRIVING FOR PERIOD OF TIME . . . . . 02-03–5
Intermittent Concern No.3 WHEEL UNIT ID REGISTRATION 02-03
Troubleshooting. . . . . . . . . . . . . . . . . 02-03–3 CANNOT BE PERFORMED
SYMPTOM TROUBLESHOOTING . . . . . 02-03–4 (TPMS WARNING LIGHT FLASHES) . . 02-03–6
Display Of M-MDS (Example) . . . . . . . . 02-03–7
End of Toc
WM: TIRE PRESSURE MONITORING SYSTEM
02-03–1
1871-1U-06B(02-03).fm 2 ページ 2006年3月15日 水曜日 午前10時57分
SYMPTOM TROUBLESHOOTING
TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING DIAGRAM
id020300800100
With Advanced Keyless System
WHEEL UNIT
KEYLESS
RF SIGNAL
RECEIVE
INSTRUMENT
CLUSTER
PCM
ANTENNA
KEYLESS CM CAN_H
2R
CAN_L
2T
A 3A 3Q 2N
C 3C
CAN
DRIVER
E 2B
2A
DLC-2
acxuuw00002407
WHEEL UNIT
RF SIGNAL
KEYLESS
INSTRUMENT
RECEIVER
CLUSTER
PCM
ANTENNA
CAN_H
2R
A
CAN_L
2T
B
CAN
D 2N DRIVER
2A
DLC-2
acxuuw00002408
End Of Sie
FOREWORD
id020300800200
• Before performing the steps in Symptom Troubleshooting, perform the On-board Diagnostic Inspection. To
check the DTC, follow the DTC Inspection steps. (See 02-02-3 TIRE PRESSURE MONITORING SYSTEM
(TPMS) ON-BOARD DIAGNOSIS.)
End Of Sie
02-03–2
1871-1U-06B(02-03).fm 3 ページ 2006年3月15日 水曜日 午前10時57分
SYMPTOM TROUBLESHOOTING
PRECAUTION
id020300800300
Intermittent Concern Troubleshooting
Vibration method
• If malfunction occurs or becomes worse while driving on a rough road or when the engine is vibrating, perform
the steps below.
Note
• There are several reasons why vehicle or engine vibration could cause an electrical malfunction. Some of
the things to check for are:
— Connectors not fully seated. 02-03
— Wire harnesses not having full play.
— Wires laying across brackets or moving parts.
— Wires routed too close to hot parts.
• An improperly routed, improperly clamped, or loose harness can cause wiring to become pinched
between parts.
• The connector joints, points of vibration, and places where wire harnesses pass through the firewall, body
panels and other panels are the major areas to be checked.
Note
• If engine starts and runs, perform the following steps at idle.
acxuuw00000958
Note
• If engine starts and runs, perform the following steps at idle.
02-03–3
1871-1U-06B(02-03).fm 4 ページ 2006年3月15日 水曜日 午前10時57分
SYMPTOM TROUBLESHOOTING
Connector terminal check method
1. Check the connection condition of each female terminal.
2. Insert male terminal; fit the female terminal side
to female terminal and check to see whether the
malfunction is in the female terminal or not.
End Of Sie
acxuuw00000959
SYMPTOM TROUBLESHOOTING
id020300800400
No. Symptom
1 TPMS warning light illuminates continuously.
TPMS warning light (low pressure warning) illuminates after engine start and turns off after driving for a period
2
of time.
3 Wheel unit ID registration cannot be performed (TPMS warning light flashes).
End Of Sie
No.1 TPMS WARNING LIGHT ILLUMINATES CONTINUOUSLY
id020300800500
Caution
• The tire pressure cannot be measured accurately after driving for a long period due to the internal
temperature and pressure. Stop the vehicle for approx. 1 hour and then perform the tire pressure
measurement and adjustment.
• Use a high accuracy digital gauge for measurement of the tire pressure.
Note
• If the DTC clearing procedure is implement, the TPMS warning light turns off.
Note
• If the TPMS warning light does not turn off after
repeating this step, the tire may be flat.
End Of Sie
02-03–4
1871-1U-06B(02-03).fm 5 ページ 2006年3月15日 水曜日 午前10時57分
SYMPTOM TROUBLESHOOTING
No.2 TPMS WARNING LIGHT (LOW PRESSURE WARNING) ILLUMINATES AFTER ENGINE START AND
TURNS OFF AFTER DRIVING FOR PERIOD OF TIME
id020300800600
Caution
• The tire pressure cannot be measured accurately after driving for a long period due to increased
internal temperature and pressure. Stop the vehicle for approx. 1 hour and then perform the tire
pressure measurement and adjustment.
• Use a high accuracy digital gauge for measurement of the tire pressure.
Note
02-03
• The tire pressure normally decreases by approx. 7 kPa {0.07 kgf/cm2, 1.02 psi} per month even if the
tire is normal.
• The FFD (temperature and pressure) stored when the TPMS warning light is turned on or off can be
verified by operating the M-MDS.
TPMS warning light (low pressure warning) illuminates after engine start and turns off after driving
2
for a period of time.
[TROUBLESHOOTING HINTS]
• The tire pressure decreases (approaches value to illuminate TPMS warning light) when the internal temperature of the tire
is low.
End Of Sie
02-03–5
1871-1U-06B(02-03).fm 6 ページ 2006年3月15日 水曜日 午前10時57分
SYMPTOM TROUBLESHOOTING
No.3 WHEEL UNIT ID REGISTRATION CANNOT BE PERFORMED (TPMS WARNING LIGHT FLASHES)
id020300800900
Caution
• Activate the wheel unit ID registration mode using the M-MDS, and perform the following steps if
the TPMS warning light does not turn off after driving at 25 km/h {15.5 mph} or more for 10 min or
more.
Note
• If the battery is removed, the tire
pressure data for WU_1 to WU_4
stored in the instrument cluster is
reset.
• Pressure is 0 kPa {0 kgf/cm2, 0 psi}
when it is displayed again using the M-
MDS.
02-03–6
1871-1U-06B(02-03).fm 7 ページ 2006年3月15日 水曜日 午前10時57分
SYMPTOM TROUBLESHOOTING
Display Of M-MDS (Example)
Registered ID: 0xAAAAAAAA, 0xBBBBBBBB, 0xCCCCCCCC, and 0xDDDDDDDD (AAAAAAAA, BBBBBBBB,
CCCCCCCC, and DDDDDDDD mean arbitrary numbers.)
Unregistered ID: 0x00000000
Tire pressure: aaa kPa, bbb kPa, ccc kPa, ddd kPa (aaa, bbb, ccc, and ddd mean measurement value.)
* The battery is removed, the stored tire pressure is reset to 0 kPa.
When a replaced wheel unit and two registered wheel units malfunctions
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0x00000000 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) 0 kPa 0 kPa 0 kPa 0 kPa
02-03–7
1871-1U-06B(02-03).fm 8 ページ 2006年3月15日 水曜日 午前10時57分
SYMPTOM TROUBLESHOOTING
When a registered wheel unit malfunctions
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0xFFFFFFFF 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa fff kPa 0 kPa 0 kPa
When two replaced wheel units and a registered wheel unit malfunction
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0x00000000 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) aaa kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) 0 kPa 0 kPa 0 kPa 0 kPa
When a replaced wheel unit and two registered wheel units malfunction
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) 0 kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa 0 kPa 0 kPa 0 kPa
02-03–8
1871-1U-06B(02-03).fm 9 ページ 2006年3月15日 水曜日 午前10時57分
SYMPTOM TROUBLESHOOTING
When a replaced wheel unit and a registered wheel unit malfunction
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0xFFFFFFFF 0x00000000 0x00000000
Tire Pressure (Stored) 0 kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa fff kPa 0 kPa 0 kPa
When two replaced wheel units and a registered wheel unit malfunction
WU_1 WU_2 WU_3 WU_4
ID Number (Stored) 0xAAAAAAAA 0xBBBBBBBB 0xCCCCCCCC 0xDDDDDDDD
ID Number (Candidate) 0xEEEEEEEE 0x00000000 0x00000000 0x00000000
Tire Pressure (Stored) 0 kPa 0 kPa 0 kPa 0 kPa
Tire Pressure (Candidate) eee kPa 0 kPa 0 kPa 0 kPa
End Of Sie
02-03–9
1871-1U-06B(02-10).fm 1 ページ 2006年3月15日 水曜日 午前10時58分
GENERAL PROCEDURES
02-10 GENERAL PROCEDURES
PRECAUTION (SUSPENSION). . . . . . . . 02-10–1 Brake Lines
Wheels and Tires Disconnection/Connection . . . . . . . . . 02-10–1
Removal/Installation. . . . . . . . . . . . . . 02-10–1 Power Steering Components
Suspension Links Removal/Installation . . . . . . . . . . . . . . 02-10–1
Removal/Installation. . . . . . . . . . . . . . 02-10–1
End of Toc
PRECAUTION (SUSPENSION)
WM: SUSPENSION
02-10
id021000800100
Wheels and Tires Removal/Installation
1. When a wheel is installed, tighten it to
88.2— 117.6 N·m {9.00— 11.99 kgf·m, 65.06—
86.73 ft·lbf}.
1
4 3
2 5
acxuuw00001032
Note
• Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack and tools
are in designated position.
Caution
• Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off
immediately.
1. Tighten the brake pipe flare nut using the SST (49 0259 770B). Be sure to modify the brake pipe flare nut
tightening torque to allow for use of a torque wrench-SST combination.
(See 00-00-13 SERVICE CAUTIONS.)
2. If any brake line has been disconnected anytime during the procedure, add brake fluid, bleed the brakes, and
inspect for leakage after the procedure has been completed.
End Of Sie
02-10–1
1871-1U-06B(02-11).fm 1 ページ 2006年3月15日 水曜日 午前10時59分
WHEEL ALIGNMENT
02-11 WHEEL ALIGNMENT
WHEEL ALIGNMENT Steering Angle Adjustment . . . . . . . . . . 02-11–2
PRE-INSPECTION . . . . . . . . . . . . . . . . 02-11–1 Camber and Caster Adjustment . . . . . . 02-11–3
FRONT WHEEL ALIGNMENT . . . . . . . . 02-11–2 Total Toe-in Adjustment . . . . . . . . . . . . . 02-11–3
REAR WHEEL ALIGNMENT . . . . . . . . . . 02-11–4
Total Toe-in Adjustment . . . . . . . . . . . . . 02-11–4
End of Toc
WHEEL ALIGNMENT PRE-INSPECTION
WM: SUSPENSION
02-11
id021100800100
1. Park the vehicle on a level ground, in an unloaded condition*, and with the wheels straight forward.
*
: Unloaded condition.....Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack
and tools are in designated position.
2. Inspect the tire pressure.
• Adjust to the recommended pressure if necessary. (See 02-50-1 SUSPENSION TECHNICAL DATA.)
3. Inspect the wheel bearing play.
• Correct if necessary. (See 03-11-2 WHEEL HUB, STEERING KNUCKLE INSPECTION.) (See 03-12-2
WHEEL HUB COMPONENT INSPECTION.)
4. Inspect the wheel runout.
• Correct if necessary. (See 02-50-1 SUSPENSION TECHNICAL DATA.)
5. Rock the vehicle, and verify that there is no looseness in the steering wheel joint and suspension ball joint.
6. Rock the vehicle, and verify that the shock absorber operates properly.
7. Measure height H from the center of the wheel to FENDER BRIM
the fender brim. SEC. A-A MEASUREMENT POINT
8. Verify that the difference between the left and
A
right dimension H is within the specification.
• If it exceeds the specification, repeat the Step
2— 7.
H
A
Standard
10 mm {0.39 in} or less
End Of Sie
WM: FRONT SUSPENSION
acxuuw00001033
02-11–1
1871-1U-06B(02-11).fm 2 ページ 2006年3月15日 水曜日 午前10時59分
WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT
id021100800200
*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2 : Difference between left and right must not exceed 1°30′.
Note
Total toe-in measuring position
• Tire: A indicated in the figure (between the A
center of the tires)
• Rim inner: B indicated in the figure (between
the inner side of the rims)
B
acxuuw00000347
Note
• The travel distance of the right and left tie rods should be the same.
Tightening torque
acxuuw00000348
68.6— 98.0 N·m {7.00— 9.99 kgf·m, 50.6—
72.2 ft·lbf}
02-11–2
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
WHEEL ALIGNMENT
Camber and Caster Adjustment
1. Remove the windshield wiper arm. (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE REMOVAL/
INSTALLATION.)
2. Remove the cowl grille. (See 09-16-11 COWL GRILLE REMOVAL/INSTALLATION.)
3. Jack up the front of the vehicle and support it on safety stands.
4. Remove the mounting rubber nuts.
02-11
DIRECTION
INDICATOR
acxuuw00002203
C C
A B B A
6. Install the shock absorber and coil spring, then tighten the mounting rubber nuts to the specified torque.
Tightening torque
46.1— 62.7 N·m {4.71— 6.39 kgf·m, 34.1— 46.2 ft·lbf}
Note
• Toe angle changes by approx. 6 mm {0.2 in} per one rotation of the tie rod for one wheel.
• Each tie rod has a right-hand thread. When increasing the toe-in angle, rotate the right tie rod toward the
front of the vehicle and rotate the left tie rod toward the rear of the vehicle by the same amount.
Tightening torque
68.6— 98.0 N·m {7.00— 9.99 kgf·m, 50.6— 72.2 ft·lbf}
6. Verify that the rack boot does not have any twisting and install the rack boot clamp.
End Of Sie
id021100800300
*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2 : Difference between left and right must not exceed 1°30′.
Note
Total toe-in measuring position
• Tire: A indicated in the figure (between the A
center of the tires)
• Rim inner: B indicated in the figure (between
the inner side of the rims)
B
acxuuw00001034
Tightening torque
80— 100 N·m {8.2— 10.1 kgf·m, 59.1— 73.7 ADJUSTING CAM BOLT
ft·lbf}
acxuuw00001035
End Of Sie
02-11–4
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
WHEEL AND TIRES
02-12 WHEEL AND TIRES
WHEEL AND TIRE SPECIFICATION . . . 02-12–1 WHEEL UNIT ID REGISTRATION . . . . . . 02-12–4
WHEEL BALANCE ADJUSTMENT . . . . 02-12–2 Using M-MDS . . . . . . . . . . . . . . . . . . . . 02-12–4
Adhesive-type Balance Weight Without Using M-MDS. . . . . . . . . . . . . . 02-12–4
(Outer). . . . . . . . . . . . . . . . . . . . . . . . 02-12–2 WHEEL UNIT
Knock-type Balance Weight (Inner) . . . 02-12–3 REMOVAL/INSTALLATION . . . . . . . . . . 02-12–4
Remaining Amount of Unbalance Valve Core Removal Note . . . . . . . . . . . 02-12–5
Confirmation. . . . . . . . . . . . . . . . . . . . 02-12–3 Wheel Unit Removal Note . . . . . . . . . . . 02-12–5
TIRE PRESSURE ADJUSTMENT Wheel Unit Installation Note . . . . . . . . . 02-12–6 02-12
(WITH TPMS) . . . . . . . . . . . . . . . . . . . . 02-12–3
End of Toc
WHEEL AND TIRE SPECIFICATION
WM: WHEELS AND TIRES
id021200800100
End Of Sie
Caution
• Adjust the outer wheel balance first, then the inner wheel balance.
• Be careful not to scratch the wheels.
Caution
• Use a genuine balance weight or equivalent (steel).
• When attaching the weight, press the weight with a force of 25 N {2.5 kgf, 5.5 lbf} per 5 g for 2 s or
more.
Caution
• Do not attach weight balances in a row.
• Do not overlap the balance weights.
• Total weight must not exceed 160 g {5.65
oz}. POSITION INDICATED BY WHEEL BALANCER
NO GOOD NO GOOD
(DO NOT ATTACH (DO NOT OVERLAP)
IN A ROW)
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02-12–2
1871-1U-06B(02-12).fm 3 ページ 2006年3月15日 水曜日 午前10時59分
acxuuw00001038
Specifications
Outer (Adhesive-type): 10 g {0.35 oz}
Inner (Knock-type): 6 g {0.21 oz}
End Of Sie
TIRE PRESSURE ADJUSTMENT (WITH TPMS)
id021200800300
1. Use of a digital gauge is recommended for accurate measurement of the air pressure.
2. Tire pressure lowers gradually as time passes. Due to this, monthly air pressure inspection is recommended.
3. Perform tire pressure adjustment before driving. (When tires are cold.)
• Tire pressure will increase after driving because the internal temperature of the tire is high. If tire pressure
is adjusted to specifications when the internal temperature of the tire is high, tire pressure will decrease
when the internal temperature of the tire decreases to the same level as ambient temperature. If the tire
pressure is lower than the lower-limit pressure, the TPMS warning light may illuminate.
• Even though the air pressure is adjusted to specifications, the indicated air pressure may be higher than the
specified value when the internal temperature of the tire is higher than ambient temperature. (Example: Air
pressure changes approx. 10 kPa {0.1 kgf/cm2, 1.5 psi} when the temperature changes 10 °C {18 °F})
Caution
• In an area or a season with varying temperatures, tire pressure will change due to ambient
temperature change. If the tire pressure is lower than the lower-limit pressure due to low ambient
temperature, the TPMS warning light may illuminate. Adjust the pressure when the TPMS warning
light illuminates.
• Do not tilt or use excessive side force when checking air pressure or inflating the tire with air.
Which can provide enough leverage to easily bend or break the wheel unit.
• To prevent damage to the valve area of
the wheel unit or pressure loss during air
pressure adjustment, use a type B tool TYPE A TYPE B
with a round end as shown in the figure,
not a type A tool.
End Of Sie
WM: TIRE PRESSURE MONITORING SYSTEM
acxuuw00001039
02-12–3
1871-1U-06B(02-12).fm 4 ページ 2006年3月15日 水曜日 午前10時59分
Note
• After the wheel unit replacement, registration of the wheel unit identification codes must be performed.
• ID registration can be done using the M-MDS, or not using the M-MDS.
Using M-MDS
1. After the vehicle is identified, select the following items from the initialization screen of the M-MDS.
• This function is available for only the IDS (notebook PC).
1. Select the “Body” tab.
2. Select the “TPMS Functions”.
3. Select the “Wheel Unit ID Registration”.
2. Leave the vehicle with the engine off for 15 min or more.
3. Verify that the TPMS warning light turns on and off in 0.5 s cycles repeatedly.
4. Drive the vehicle at a speed of 25 km/h {15.5 mph} or more for 10 min to implement the wheel unit ID
registration.
Note
• If the ID registration is not completed even after driving the vehicle for 10 min or more at a speed of 25
km/h {15.5 mph} or more, the TPMS warning light flashes.
Note
• If the wheel unit ID registration cannot be performed after driving 10 min or more, refer to the symptom
troubleshooting procedure.
id021200800600
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. When replacing wheel unit (s), register the new wheel unit ID (s). (See 02-12-4 WHEEL UNIT ID
REGISTRATION.)
Note
• If the wheel unit is replaced with a new one, the ID registration must be performed. When the ID
registration is finished, the data for the new wheel unit is displayed on the M-MDS.
02-12–4
1871-1U-06B(02-12).fm 5 ページ 2006年3月15日 水曜日 午前10時59分
2 R
3 R
7.5—8.5 02-12
{77—86, 67—75}
5 R
6
R
acxuuw00001040
Caution
• Breaking the tire bead with the wheel unit installed normally could damage the unit. Be sure to
always push the wheel unit so that it is completely inside the tire to prevent any damage.
2. Position the shoe (bead breaker) of the tire changer 10— 20 mm {0.40— 0.78 in} from the outer edge of the
wheel, and break both tire beads.
3. Remove the bead from one side of the wheel.
4. Remove the wheel unit.
02-12–5
1871-1U-06B(02-12).fm 6 ページ 2006年3月15日 水曜日 午前10時59分
Note
• Maintain the wheel unit in contact with the
rim, then start manually to screw the valve
nut for a few turns.
Caution
• Do not position the tire changer near the
tire valve to avoid any damage to the
wheel unit.
TIRE ROTATION
VALVE DIRECTION
45°
VALVE
THE ARM OF
THE TIRE
45° CHANGER
5. Fill the tire with air and verify the valve nut
tightening torque.
TYPE A TYPE B
Caution
• To prevent damage to the valve area of
the wheel unit or charging loss during air
pressure adjustment, use a type B tool
with a round end as shown in the figure,
not a type A tool.
End Of Sie
acxuuw00001043
02-12–6
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
FRONT SUSPENSION
02-13 FRONT SUSPENSION
FRONT SUSPENSION FRONT STABILIZER
LOCATION INDEX. . . . . . . . . . . . . . . . . 02-13–2 REMOVAL/INSTALLATION . . . . . . . . . . 02-13–8
FRONT SHOCK ABSORBER Front Stabilizer Installation Note . . . . . . 02-13–8
AND SPRING Stabilizer Bushing Installation Note. . . . 02-13–9
REMOVAL/INSTALLATION . . . . . . . . . 02-13–3 Stabilizer Bracket Installation Note . . . . 02-13–9
Front Shock Absorber and STABILIZER CONTROL LINK
Coil Spring Installation Note. . . . . . . . 02-13–3 INSPECTION . . . . . . . . . . . . . . . . . . . . . 02-13–9
FRONT CROSSMEMBER 02-13
Cap Installation Note . . . . . . . . . . . . . . 02-13–4 REMOVAL/INSTALLATION . . . . . . . . . . 02-13–10
FRONT SHOCK ABSORBER AND Tie-rod End Ball Joint
SPRING DISASSEMBLY/ Removal Note. . . . . . . . . . . . . . . . . . . 02-13–11
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 02-13–4 Steering Gear And Linkage,
Piston Rod Nut Disassembly Note . . . . 02-13–5 Front Stabilizer, Front Lower Arm
Coil Spring Assembly Note . . . . . . . . . 02-13–5 And Front Crossmember
Upper Spring Seat Assembly Note . . . 02-13–5 Component Removal Note . . . . . . . . . 02-13–11
Mounting Rubber Assembly Note . . . . 02-13–6 Front Crossmember Mounting
FRONT SHOCK ABSORBER Rubber (front) Installation Note . . . . . . 02-13–12
INSPECTION . . . . . . . . . . . . . . . . . . . . . 02-13–6 Front Crossmember Mounting
FRONT SHOCK ABSORBER Rubber (rear) Installation Note . . . . . . 02-13–12
DISPOSAL . . . . . . . . . . . . . . . . . . . . . . 02-13–6 Steering Gear And Linkage,
FRONT LOWER ARM Front Stabilizer, Front Lower Arm
REMOVAL/INSTALLATION. . . . . . . . . . 02-13–7 And Front Crossmember
FRONT LOWER ARM INSPECTION . . . 02-13–7 Component Installation Note. . . . . . . . 02-13–13
TRANSVERSE MEMBER
REMOVAL/INSTALLATION . . . . . . . . . . 02-13–14
End of Toc
WM: SUSPENSION
acxuuw00001673
End Of Sie
WM: FRONT SHOCK ABSORBER AND SPRING
02-13–2
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
FRONT SUSPENSION
FRONT SHOCK ABSORBER AND SPRING REMOVAL/INSTALLATION
id021300800200
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. Remove the windshield wiper arm. (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE REMOVAL/
INSTALLATION.)
2. Remove the cowl grille. (See 09-16-11 COWL GRILLE REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table. 02-13
4. Install in the reverse order of removal.
5. Inspect for front wheel alignment, and adjust it as necessary. (See 02-11-2 FRONT WHEEL ALIGNMENT.)
4
46.1—62.7 {4.71—6.39,
34.1—46.2} 5
163.0—194.0
{16.7—19.7,
120.3—143.0}
2
7.8—10.8 N·m
{79.6—110.1 kgf·cm,
69.1—95.5 in·lbf}
acxuuw00002562
acxuuw00001046
Caution
• If the pad in the strut mount area is removed, clean the attachment surface and install the cap. If
the cap is not installed, the front shock absorber may corrode due to water penetration and cause
a malfunction.
End Of Sie
FRONT SHOCK ABSORBER AND SPRING DISASSEMBLY/ASSEMBLY
id021300800300
1. Remove the front shock absorber and coil spring. (See 02-13-3 FRONT SHOCK ABSORBER AND SPRING
REMOVAL/INSTALLATION.)
Warning
• Removing/installing the piston rod nut is dangerous. The shock absorber and spring could fly off
under tremendous pressure and cause serious injury or death. Secure the shock absorber in the
SSTs before removing the piston rod nut.
R SST
1 89.2—127.4
{9.10—12.99,
2 65.8—93.9}
SST 9
3
10 5
11 7
RUBBER
GREASE
8 GREASE
acxuuw00001060
FRONT SUSPENSION
Piston Rod Nut Disassembly Note
Warning
• Removing the piston rod nut is dangerous. The shock absorber and spring could fly off under
tremendous pressure and cause serious injury or death. Secure the shock absorber in the SSTs
before removing the piston rod nut.
1. Protect the coil spring using a piece of cloth, then set the SSTs.
2. Compress the coil spring using the SSTs, and
49 T034 1A0
remove the piston rod nut.
02-13
ampjjw00000644
49 T034 1A0
ampjjw00000536
LH RH
OUT OUT
SIDE SIDE
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02-13–5
1871-1U-06B(02-13).fm 6 ページ 2006年3月15日 水曜日 午前11時0分
FRONT SUSPENSION
Mounting Rubber Assembly Note
1. Slide the mounting rubber identification mark
away from the notch of the spring seat and install. FRONT
End Of Sie
WM: FRONT SHOCK ABSORBER
LH RH
IDENTIFICATION
MARK
45˚ ± 5˚
45˚ ± 5˚
acxuuw00001062
Warning
• Whenever drilling into a shock absorber, wear protective eye wear. The gas in the shock absorber
is pressurized, and could spray metal chips into the eyes and face when drilling.
1. Clamp a shock absorber on a flat surface or with the piston pointing downwards.
2. Drill a 2— 3 mm {0.08— 0.12 in} hole at a point
20— 30 mm {0.8— 1.2 in} from the bottom of the
tube, so that the gas can escape. DRILLING LOCATION
3. Turn the hole downwards. 20—30 mm
4. The oil can be collected by moving the piston rod {0.8—1.2 in}
several times up and down and cutting the tube at
the end.
5. Dispose of waste oil according to the waste
disposal law.
Note
• Shock absorber gas is nitrogen gas.
• Shock absorber oil is mineral oil.
acxuuw00001104
End Of Sie
WM: FRONT LOWER ARM
02-13–6
1871-1U-06B(02-13).fm 7 ページ 2006年3月15日 水曜日 午前11時0分
FRONT SUSPENSION
FRONT LOWER ARM REMOVAL/INSTALLATION
id021300800600
1. Remove the under cover.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
47.0—59.0
{4.80—6.01,
34.7—43.5} 7.8—10.8 N·m
{80—110 kgf·cm,
69.1—95.5 in·lbf}
02-13
R
85.7—100.0
{8.74—10.19, 1
63.21—73.75}
85.7—100.0 43.1—58.8
{8.74—10.19, {4.40—5.99,
63.21—73.75} 31.8—43.3}
A
3
43.1—60.8
{4.32—6.12,
31.2—44.3} 4
2
5
SST
N·m {kgf·m, ft·lbf}
acxuuw00001260
End Of Sie
FRONT LOWER ARM INSPECTION
id021300800700
1. Remove the lower arm from the vehicle.
2. Inspect the arm for bending or damage, and the ball joint for excessive looseness.
• If there is any malfunction, replace the lower arm.
3. Rotate the ball joint stud 5 times. Install the SST
and M6 bolt (bolt length (measured from below
the head): 20 mm {0.79 in}) to the ball joint stud,
measure the rotational torque using a torque
wrench.
• If not within the specification, replace the
lower arm.
M6 BOLT
(BOLT LENGTH
Front lower arm rotational torque (MEASURED FROM
1.4— 2.0 N·m {15— 20 kgf·cm, 13— 17 in·lbf} BELOW THE HEAD):
49 FT01 389
20 mm {0.79 in})
End Of Sie
WM: FRONT STABILIZER acxuuw00001103
02-13–7
1871-1U-06B(02-13).fm 8 ページ 2006年3月15日 水曜日 午前11時0分
FRONT SUSPENSION
FRONT STABILIZER REMOVAL/INSTALLATION
id021300800400
1. Remove the side cover and under cover.
2. Drain the power steering fluid. (See 06-14-3 POWER STEERING FLUID INSPECTION.)
3. Remove the transverse member. (See 02-13-14 TRANSVERSE MEMBER REMOVAL/INSTALLATION.)
4. Remove the front crossmember component. (See 02-13-10 FRONT CROSSMEMBER REMOVAL/
INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
43.1—60.8
2 {4.40—6.19,
31.8—44.8}
5 3
42.3—60.1 4
GREASE
RUBBER 1
{4.32—6.12,
31.2—44.3}
GREASE
42.3—60.1
{4.32—6.12,
31.2—44.3}
acxuuw00001098
POSITIONING PLATE
IDENTIFICATION
MARK
acxuuw00001099
02-13–8
1871-1U-06B(02-13).fm 9 ページ 2006年3月15日 水曜日 午前11時0分
FRONT SUSPENSION
Stabilizer Bushing Installation Note
1. Align the outer side of the positioning plate with
the stabilizer bushing. FRONT
IDENTIFICATION
MARK STABILIZER
BUSHING
02-13
POSITIONING PLATE
acxuuw00001100
ampjjw00000547
End Of Sie
WM: FRONT CROSSMEMBER
ampjjw00002979
02-13–9
1871-1U-06B(02-13).fm 10 ページ 2006年3月15日 水曜日 午前11時0分
FRONT SUSPENSION
FRONT CROSSMEMBER REMOVAL/INSTALLATION
id021300801000
1. Remove the side cover and under cover.
2. Drain the power steering fluid. (See 06-14-3 POWER STEERING FLUID INSPECTION.)
3. Remove the transverse member. (See 02-13-14 TRANSVERSE MEMBER REMOVAL/INSTALLATION.)
4. Remove the intermediate shaft installation bolt, and disconnect the steering shaft. (See 06-14-6 STEERING
WHEEL AND COLUMN REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. When replace the front crossmember, inspect the front wheel alignment and adjust it if necessary. (See 02-11-
2 FRONT WHEEL ALIGNMENT.)
43.1—60.8
7 {4.40—6.19,
31.8—44.8}
42.3—60.1
74.4—104.8
{4.32—6.12,
{7.59—10.68,
31.2—44.3}
54.88—77.29} 8
29.4—44.1 C
{3.00—4.49,
R
A 5
21.7—32.5}
2 SST
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
12
7.8—10.8 N·m
{80—110 kgf·cm,
11 70.0—95.5 in·lbf}
85.7—100
D {8.74—10.1,
63.3—73.3}
9 1
C
119.6—154.8
{12.20—15.78,
88.3—114.1} R
6 B
4 3 47—59
42.3—60.1 {4.8—6.0,
{4.32—6.12, 35—43}
119.6—154.8 D 31.2—44.3}
{12.20—15.78, 10 93.1—116.6 85.7—100 43.1—58.8 B
88.3—114.1} {9.50—11.88, {4.40—5.99,
68.7—85.9}
{8.74—10.1,
31.8—43.3}
A
63.3—73.3}
N·m {kgf·m, ft·lbf}
acxuuw00001942
02-13–10
1871-1U-06B(02-13).fm 11 ページ 2006年3月15日 水曜日 午前11時0分
FRONT SUSPENSION
Tie-rod End Ball Joint Removal Note
1. Remove the tie-rod end ball joint locknut.
2. Disconnect the tie-rod end ball joint using the
SST.
49 T028 3A0
02-13
ampjjw00003208
Steering Gear And Linkage, Front Stabilizer, Front Lower Arm And Front Crossmember Component
Removal Note
1. Support the crossmember component with a jack.
acxuuw00001339
acxuuw00001689
acxuuw00001690
02-13–11
1871-1U-06B(02-13).fm 12 ページ 2006年3月15日 水曜日 午前11時0分
FRONT SUSPENSION
5. Disconnect the return hose indicated in the figure.
6. Disconnect the pressure hose (power steering
pump side) indicated in the figure.
acxuuw00001691
FoMoCo
acxuuw00001341
FoMoCo
acxuuw00001342
02-13–12
1871-1U-06B(02-13).fm 13 ページ 2006年3月15日 水曜日 午前11時0分
FRONT SUSPENSION
Steering Gear And Linkage, Front Stabilizer, Front Lower Arm And Front Crossmember Component
Installation Note
1. Raise the steering gear and linkage, front
stabilizer, front lower arm and front crossmember
component to the appropriately level, and install
the return hose and pressure hose.
Tightening torque
Return hose: 7.8— 10.8 N·m {80— 110
kgf·cm, 69.1— 95.5 in·lbf}
Pressure hose (power steering pump side): 02-13
29.4— 44.1 N·m {3.00— 4.49 kgf·m, 21.7—
32.5 ft·lbf}
acxuuw00001691
Tightening torque
93.1— 116.6 N·m {9.50— 11.8 kgf·m, 68.7—
85.9 ft·lbf}
acxuuw00001692
Tightening torque
85.3— 116.6 N·m {8.70— 11.8 kgf·m, 63.0—
85.9 ft·lbf}
5. Install the steering gear and linkage, front stabilizer, front lower arm and front crossmember component.
6. Tighten the No.1 engine mount bolt (crossmember side).
End Of Sie
WM: TRANSVERSE MEMBER
02-13–13
1871-1U-06B(02-13).fm 14 ページ 2006年3月15日 水曜日 午前11時0分
FRONT SUSPENSION
TRANSVERSE MEMBER REMOVAL/INSTALLATION
id021300801100
1. Remove the transverse member.
TRANSVERSE
MEMBER
93.1—131.3
{9.50—13.38,
68.67—96.84}
93.1—131.3
{9.50—13.38,
68.67—96.84} 119.6—154.8
{12.20—15.78,
119.6—154.8 88.3—114.1}
{12.20—15.78,
88.3—114.1} N·m {kgf·m, ft·lbf}
acxuuw00001674
acxuuw00001675
Tightening torque
Nut A: 119.6— 154.8 N·m {12.20— 15.78
kgf·m, 88.3— 114.1 ft·lbf} A
Bolts B and C: 93.1— 131.3 N·m {9.50—
13.38 kgf·m, 68.67— 96.84 ft·lbf}
End Of Sie
C
B
acxuuw00001676
02-13–14
1871-1U-06B(02-14).fm 1 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
02-14 REAR SUSPENSION
REAR SUSPENSION TRAILING LINK
LOCATION INDEX[2WD] . . . . . . . . . . . 02-14–2 REMOVAL/INSTALLATION[AWD] . . . . . 02-14–15
REAR SUSPENSION Rear ABS Wheel-speed Sensor
LOCATION INDEX[AWD] . . . . . . . . . . . 02-14–3 Removal Note . . . . . . . . . . . . . . . . . . . 02-14–16
REAR SHOCK ABSORBER Brake Caliper Component
REMOVAL/INSTALLATION. . . . . . . . . . 02-14–4 Removal Note . . . . . . . . . . . . . . . . . . . 02-14–16
Nut Removal Note . . . . . . . . . . . . . . . . 02-14–5 Bolt (Rear Shock Absorber Lower Side)
REAR SHOCK ABSORBER Removal Note . . . . . . . . . . . . . . . . . . . 02-14–16 02-14
INSPECTION . . . . . . . . . . . . . . . . . . . . 02-14–5 Bolts (Rear Lateral Link Outer Side And
REAR SHOCK ABSORBER Rear Upper Arm Outer Side)
DISPOSAL . . . . . . . . . . . . . . . . . . . . . . 02-14–5 Removal Note . . . . . . . . . . . . . . . . . . . 02-14–16
REAR COIL SPRING Rear Trailing Link Component
REMOVAL/INSTALLATION. . . . . . . . . . 02-14–6 Removal Note . . . . . . . . . . . . . . . . . . . 02-14–17
Bolt (Rear Lower Arm Outer Side) Bolts (Rear Lateral Link Outer Side And
Removal Note . . . . . . . . . . . . . . . . . . 02-14–6 Rear Upper Arm Outer Side)
Rear Coil Spring Installation Note . . . . 02-14–7 Installation Note . . . . . . . . . . . . . . . . . 02-14–17
REAR LOWER ARM REAR CROSSMEMBER
REMOVAL/INSTALLATION. . . . . . . . . . 02-14–8 REMOVAL/INSTALLATION[2WD] . . . . . 02-14–18
REAR LATERAL LINK Bolt (Rear Upper Arm Outer Side And
REMOVAL/INSTALLATION. . . . . . . . . . 02-14–8 Rear Lateral Link Outer Side)
REAR UPPER ARM Removal Note . . . . . . . . . . . . . . . . . . . 02-14–19
REMOVAL/INSTALLATION. . . . . . . . . . 02-14–10 Rear Crossmember Component
REAR STABILIZER Removal Note . . . . . . . . . . . . . . . . . . . 02-14–19
REMOVAL/INSTALLATION. . . . . . . . . . 02-14–11 Bolt (Rear Upper Arm Outer Side And
Rear Stabilizer Installation Note. . . . . . 02-14–11 Rear Lateral Link Outer Side)
Bushing Installation Note . . . . . . . . . . . 02-14–12 Installation Note . . . . . . . . . . . . . . . . . 02-14–19
Stabilizer Control Link Rear Cross Bar Installation Note. . . . . . 02-14–19
Installation Note . . . . . . . . . . . . . . . . . 02-14–12 REAR CROSSMEMBER
STABILIZER CONTROL LINK REMOVAL/INSTALLATION[AWD] . . . . . 02-14–20
INSPECTION . . . . . . . . . . . . . . . . . . . . 02-14–12 Rear ABS Wheel-speed Sensor
TRAILING LINK Removal Note . . . . . . . . . . . . . . . . . . . 02-14–21
REMOVAL/INSTALLATION[2WD] . . . . 02-14–12 Brake Caliper Component
ABS Wheel-speed Sensor Removal Note . . . . . . . . . . . . . . . . . . . 02-14–21
Removal Note . . . . . . . . . . . . . . . . . . 02-14–14 Bolt (Rear Shock Absorber Lower Side)
Caliper Component Removal Note . . . 02-14–14 Removal Note. . . . . . . . . . . . . . . . . . . 02-14–21
Bolt (Rear Shock Absorber Lower Side) Bolts (Rear Lateral Link Outer Side And
Removal Note . . . . . . . . . . . . . . . . . . 02-14–14 Rear Upper Arm Outer Side)
Bolts (Rear Lateral Link Outer Side And Removal Note. . . . . . . . . . . . . . . . . . . 02-14–22
Rear Upper Arm Outer Side) Rear Crossmember And
Removal Note . . . . . . . . . . . . . . . . . . 02-14–14 Rear Differential Removal Note. . . . . . 02-14–22
Bolts (Rear Lateral Link Outer Side And Bolts (Rear Lateral Link Outer Side And
Rear Upper Arm Outer Side) Rear Upper Arm Outer Side)
Installation Note . . . . . . . . . . . . . . . . . 02-14–14 Installation Note . . . . . . . . . . . . . . . . . 02-14–22
Rear Cross Bar Installation Note. . . . . . 02-14–22
End of Toc
WM: REAR SUSPENSION
02-14–1
1871-1U-06B(02-14).fm 2 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
REAR SUSPENSION LOCATION INDEX[2WD]
id0214008004a1
9
2
6
5
A
7
VIEW FROM A
4 8
acxuuw00001677
End Of Sie
02-14–2
1871-1U-06B(02-14).fm 3 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
REAR SUSPENSION LOCATION INDEX[AWD]
id0214008004a3
02-14
9
6 5 A
7
VIEW FROM A
4 8
acxuuw00001678
End Of Sie
WM: REAR SHOCK ABSORBER
02-14–3
1871-1U-06B(02-14).fm 4 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
REAR SHOCK ABSORBER REMOVAL/INSTALLATION
id021400801300
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
24.5—34.6
{2.50—3.49, 18.1—25.2} 3
4
5
46.1—62.7 4
2
{4.71—6.39, 34.1—46.2} 1
75.5—102
{7.70—10.4, 55.7—75.2}
1 Nut 4 Retainer
(See 02-14-5 Nut Removal Note) 5 Bushing
2 Rear shock absorber component 6 Rear shock absorber
3 Piston rod nut
02-14–4
1871-1U-06B(02-14).fm 5 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
Nut Removal Note
1. Support the rear axle with the jack.
02-14
JACK
acxuuw00001975
acxuuw00001719
02-14–5
1871-1U-06B(02-14).fm 6 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
REAR COIL SPRING REMOVAL/INSTALLATION
id021400800700
1. Remove the middle pipe. (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
2. Remove the rear stabilizer. (See 02-14-11 REAR STABILIZER REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Inspect the rear wheel alignment. (See 02-11-4 REAR WHEEL ALIGNMENT.)
B 3
A
C
2
75.5—102 1
{7.70—10.4, 55.7—75.2}
B
A C
N·m {kgf·m, ft·lbf}
acxuuw00001681
JACK
acxuuw00001976
02-14–6
1871-1U-06B(02-14).fm 7 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
4. Support the lower arm with a jack.
5. Loosen the inner bolt of the lower arm.
6. Remove the outer bolt of the lower arm.
7. Jack down slowly and remove the coil spring.
Warning
• Removing the coil spring is dangerous.
The coil spring could fly off, the cause
serious injury or death.
JACK 02-14
acxuuw00002442
Warning
• Installing the coil spring is dangerous. The coil spring could fly off, and cause serious injury or
death.
Tightening torque
• 75.5— 102 N·m {10.0— 12.2 kgf·m, 72.3— 75.2 ft·lbf}
Tightening torque
• 75.5— 102 N·m {10.0— 12.2 kgf·m, 72.3— 75.2 ft·lbf}
End Of Sie
WM: REAR LOWER ARM
02-14–7
1871-1U-06B(02-14).fm 8 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
REAR LOWER ARM REMOVAL/INSTALLATION
id021400800900
1. Remove the middle pipe. (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
2. Remove the rear stabilizer. (See 02-14-11 REAR STABILIZER REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Inspect the rear wheel alignment. (See 02-11-4 REAR WHEEL ALIGNMENT.)
80—100
{8.16—10.1, 60.0—73.7}
B A
1
75.5—102
{7.70—10.4,
55.7—75.2}
B A
3
N·m {kgf·m, ft·lbf}
acxuuw00001682
1 Rear coil spring component 2 Bolt (rear lower arm inner side)
(See 02-14-6 REAR COIL SPRING REMOVAL/ 3 Rear lower arm
INSTALLATION.)
4 Bound stopper
End Of Sie
REAR LATERAL LINK REMOVAL/INSTALLATION
WM: REAR LATERAL LINKS
id021400801200
1. Raise the rear trailing link to the unloaded
condition with a jack.
Note
• Jacking up the rear suspension to the no-
occupant position will lighten the force on the
bushing and make it easier to perform the
procedure.
JACK
acxuuw00001977
02-14–8
1871-1U-06B(02-14).fm 9 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
2. Remove the rear lateral link.
75.5—102
{7.70—10.4,
55.7—75.2}
02-14
acxuuw00001684
FRONT FRONT
acxuuw00001685
02-14–9
1871-1U-06B(02-14).fm 10 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
REAR UPPER ARM REMOVAL/INSTALLATION
id021400800800
1. Raise the trailing link to the unloaded condition
with the jack.
Note
• Jacking up the rear suspension to the no-
occupant position will lighten the force on the
bushing and make it easier to perform the
procedure.
75.5—102
{7.70—10.4,
55.7—75.2}
N·m {kgf·m, ft·lbf}
acxuuw00001683
02-14–10
1871-1U-06B(02-14).fm 11 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
REAR STABILIZER REMOVAL/INSTALLATION
id021400800500
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
02-14
43.1—60.8
{4.40—6.19,
31.8—44.8}
43.1—60.8
{4.40—6.19,
43.1—60.8 31.8—44.8}
{4.40—6.19,
31.8—44.8} 4
RUBBER 3
GREASE
GREASE 2
N·m {kgf·m, ft·lbf}
acxuuw00001686
10 20
MARKING
acxuuw00001795
02-14–11
1871-1U-06B(02-14).fm 12 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
Bushing Installation Note
1. Align the outer side of the marking with the
stabilizer bushing.
FRONT
RH
MARKING
BUSHING
acxuuw00001796
WHITE MARKING
acxuuw00001797
End Of Sie
WM: REAR TRAILING LINKS
ampjjw00002979
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. Remove the middle pipe. (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
2. Remove the rear stabilizer. (See 02-14-11 REAR STABILIZER REMOVAL/INSTALLATION.)
3. Remove the rear coil spring. (See 02-14-6 REAR COIL SPRING REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Inspect the rear wheel alignment. (See 02-11-4 REAR WHEEL ALIGNMENT.)
02-14–12
1871-1U-06B(02-14).fm 13 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
78.4—101.9
{8.00—10.3,
57.9—75.1}
75.5—102
{7.70—10.4,
75.5—102 55.7—75.2} 3
{7.70—10.4,
55.7—75.2}
5 02-14
7
4
2
9.8—14.7 N·m
{100—149 kgf·cm,
87—130 in·lbf}
97.7—132.3
{9.97—13.49,
72.06—97.57}
75.5—102
6 8 {7.70—10.4,
55.7—75.2}
98—120
1 {10.0—12.2, 11
72.3—88.5} 10
02-14–13
1871-1U-06B(02-14).fm 14 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
ABS Wheel-speed Sensor Removal Note
1. Remove the rear ABS wheel-speed sensor and
rear ABS wheel-speed sensor harness connected
to the rear trailing link.
acxuuw00001786
JACK
acxuuw00001787
Bolts (Rear Lateral Link Outer Side And Rear Upper Arm Outer Side) Removal Note
1. Raise the trailing link to the unloaded condition
with a jack.
Note
• Jacking up the rear suspension to the no-
occupant position will lighten the force on the
bushing and make it easier to perform the
procedure.
Bolts (Rear Lateral Link Outer Side And Rear Upper Arm Outer Side) Installation Note
1. Raise the rear trailing link to the unloaded
condition with a jack.
Note
• Jacking up the rear suspension to the no-
occupant position will lighten the force on the
bushing and make it easier to perform the
procedure.
02-14–14
1871-1U-06B(02-14).fm 15 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
TRAILING LINK REMOVAL/INSTALLATION[AWD]
id0214008001a3
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. Remove the middle pipe. (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC]
2. Remove the rear stabilizer. (See 02-14-11 REAR STABILIZER REMOVAL/INSTALLATION
02-14
3. Remove the rear coil spring. (See 02-14-6 REAR COIL SPRING REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Inspect the rear wheel alignment. (See 02-11-4 REAR WHEEL ALIGNMENT.)
78.4—101.9
{8.00—10.3,
57.9—75.1}
75.5—102
{7.70—10.4, 4
75.5—102 55.7—75.2}
{7.70—10.4,
55.7—75.2}
6
8
5
235—275
2 {23.97—28.04,
173.4—202.8}
3 R
97.7—132.3
{9.97—13.49,
72.06—97.57}
75.5—102
7 9 {7.70—10.4,
55.7—75.2}
9.8—14.7 N·m
{100—149 kgf·cm,
87—130 in·lbf}
98—120
1 {10.0—12.2, 12
72.3—88.5} 11
10
acxuuw00001790
02-14–15
1871-1U-06B(02-14).fm 16 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
5 Disc plate 8 Bolt (rear upper arm outer side)
(See 04-11-22 REAR BRAKE (DISC) REMOVAL/ (See 02-14-16 Bolts (Rear Lateral Link Outer Side
INSTALLATION.) And Rear Upper Arm Outer Side) Removal Note.)
6 Bolt (rear shock absorber lower side) (See 02-14-17 Bolts (Rear Lateral Link Outer Side
(See 02-14-16 Bolt (Rear Shock Absorber Lower And Rear Upper Arm Outer Side) Installation Note.)
Side) Removal Note.) 9 Trailing link, rear wheel hub component and parking
7 Bolt (rear lateral link outer side) brake component
(See 02-14-16 Bolts (Rear Lateral Link Outer Side 10 Rear wheel hub component
And Rear Upper Arm Outer Side) Removal Note.) 11 Parking brake component
(See 02-14-17 Bolts (Rear Lateral Link Outer Side
And Rear Upper Arm Outer Side) Installation Note.) 12 Trailing link
acxuuw00001786
JACK
acxuuw00001787
Bolts (Rear Lateral Link Outer Side And Rear Upper Arm Outer Side) Removal Note
1. Raise the trailing link to the unloaded condition
with a jack.
Note
• Jacking up the rear suspension to the no-
occupant position will lighten the force on the
bushing and make it easier to perform the
procedure.
02-14–16
1871-1U-06B(02-14).fm 17 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
Rear Trailing Link Component Removal Note
1. Support the trailing link with a jack.
Caution
• Removing the trailing link is dangerous.
The trailing link could fall and cause
serious injury or death. Verify that the
jack securely supports the trailing link.
Bolts (Rear Lateral Link Outer Side And Rear Upper Arm Outer Side) Installation Note
1. Raise the rear trailing link to the unloaded
condition with a jack.
Note
• Jacking up the rear suspension to the no-
occupant position will lighten the force on the
bushing and make it easier to perform the
procedure.
02-14–17
1871-1U-06B(02-14).fm 18 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
REAR CROSSMEMBER REMOVAL/INSTALLATION[2WD]
id0214008010a1
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
97.7—132
{9.97—13.4, 72.1—97.3} 43.1—60.8
{4.40—6.19,
31.8—44.8} 75.5—102
7 {7.70—10.4,
55.7—75.2}
8
1 75.5—102
{7.70—10.4,
5 55.7—75.2}
2
97.7—132
{9.97—13.4,
43.1—60.8 75.5—102
72.1—97.3}
{4.40—6.19, {7.70—10.4,
31.8—44.8} 55.7—75.2}
6
3 75.5—102
{7.70—10.4,
55.7—75.2}
acxuuw00001928
02-14–18
1871-1U-06B(02-14).fm 19 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
Bolt (Rear Upper Arm Outer Side And Rear Lateral Link Outer Side) Removal Note
1. Raise the rear trailing link to the unloaded
condition with a jack.
Note
• Jacking up the rear suspension to the no-
occupant position will lighten the force on the
bushing and make it easier to perform the
procedure.
2. Remove the bolts (rear upper arm outer side and 02-14
rear lateral link outer side). JACK
acxuuw00001979
Warning
• Removing the crossmember is dangerous. The crossmember component could fall and cause
serious injury or death. Verify that the jack securely supports the crossmember component.
JACK
acxuuw00001528
Bolt (Rear Upper Arm Outer Side And Rear Lateral Link Outer Side) Installation Note
1. Raise the rear trailing link to the unloaded
condition with a jack.
2. Tighten the bolts (rear upper arm outer side and
rear lateral link outer side).
JACK
acxuuw00001979
FRONT
TRIANGULAR
MARKING
acxuuw00001929
02-14–19
1871-1U-06B(02-14).fm 20 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
REAR CROSSMEMBER REMOVAL/INSTALLATION[AWD]
id0214008010a3
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
13
97.7—132 43.1—60.8
{9.97—13.4, {4.40—6.19, 75.5—102 43.1—60.8
72.1—97.3} 31.8—44.8} {7.70—10.4, {4.40—6.19,
55.7—75.2} 31.8—44.8}
75.5—102
A 19 {7.70—10.4,
55.7—75.2}
78.4—101.9
B 75.5—102 {8.00—10.3,
20 {7.70—10.4, 95.9—75.1}
75.5—102 55.7—75.2}
{7.70—10.4, 4
55.7—75.2} 75.5—102
18 {7.70—10.4,
C 55.7—75.2}
D 7
6
9
75.5—102
43.1—60.8 97.7—132
75.5—102 {7.70—10.4, 5
{4.40—6.19, {9.97—13.4,
{7.70—10.4, 55.7—75.2} 17
55.7—75.2}
31.8—44.8} 72.1—97.3}
F
E
43.1—60.8
A {4.40—6.19,
31.8—44.8}
10
97.7—132.3
8 75.5—102
15 {9.97—13.49, {7.70—10.4, 1
16 72.06—97.57} 55.7—75.2} R
B 235—275
C {23.97—28.04,
14 9.8—14.7 N·m 173.4—202.8}
{100—149 kgf·cm,
11 87—130 in·lbf}
12
15 18.6—25.5
75.5—102
{1.90—2.60,
{7.70—10.4, D 2 13.8—18.8}
55.7—75.2}
3 EF
02-14–20
1871-1U-06B(02-14).fm 21 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
3 Parking brake cable 10 Rear trailing link and wheel hub component
4 Brake caliper component (See 02-14-15 TRAILING LINK REMOVAL/
(See 02-14-21 Brake Caliper Component Removal INSTALLATION[AWD].)
Note) 11 Differential oil temperature sensor connector
5 Disc plate 12 AWD solenoid connector
(See 04-11-22 REAR BRAKE (DISC) REMOVAL/ 13 Rear crossmember and rear differential component
INSTALLATION.) (See 02-14-22 Rear Crossmember And Rear
6 Rear cross bar Differential Removal Note.)
(See 02-14-22 Rear Cross Bar Installation Note.) 14 Rear differential mounting rubber
7 Bolt (rear shock absorber lower side) 15 Front differential mounting rubber
(See 02-14-21 Bolt (Rear Shock Absorber Lower
02-14
Side) Removal Note.) 16 Rear differential
8 Bolt (rear lateral link outer side) 17 Rear lateral link
(See 02-14-22 Bolts (Rear Lateral Link Outer Side 18 Rear upper arm
And Rear Upper Arm Outer Side) Removal Note.) 19 Dynamic damper
(See 02-14-22 Bolts (Rear Lateral Link Outer Side 20 Rear crossmember
And Rear Upper Arm Outer Side) Installation Note.)
9 Bolt (rear upper arm outer side)
(See 02-14-22 Bolts (Rear Lateral Link Outer Side
And Rear Upper Arm Outer Side) Removal Note.)
(See 02-14-22 Bolts (Rear Lateral Link Outer Side
And Rear Upper Arm Outer Side) Installation Note.)
acxuuw00001786
JACK
acxuuw00001787
02-14–21
1871-1U-06B(02-14).fm 22 ページ 2006年3月15日 水曜日 午前11時1分
REAR SUSPENSION
Bolts (Rear Lateral Link Outer Side And Rear Upper Arm Outer Side) Removal Note
1. Raise the rear trailing link to the unloaded
condition with a jack.
Note
• Jacking up the rear suspension to the no-
occupant position will lighten the force on the
bushing and make it easier to perform the
procedure.
Warning
• Removing the crossmember is dangerous. The crossmember component could fall and cause
serious injury or death. Verify that the jack securely supports the crossmember component.
JACK
acxuuw00001529
Bolts (Rear Lateral Link Outer Side And Rear Upper Arm Outer Side) Installation Note
1. Raise the rear trailing link to the unloaded
condition with a jack.
Note
• Jacking up the rear suspension to the no-
occupant position will lighten the force on the
bushing and make it easier to perform the
procedure.
FRONT
TRIANGULAR
MARKING
acxuuw00001794
02-14–22
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
TECHNICAL DATA
02-50 TECHNICAL DATA
SUSPENSION TECHNICAL DATA . . . . . 02-50–1
End of Toc
SUSPENSION TECHNICAL DATA
WM: SUSPENSION
id025000800100
*1
Front wheel alignment (Unloaded)
Fuel gauge indication
Item 02-50
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner 36°06′
[Tolerance ±3°] Outer 30°54′
[Tolerance ±2 {±0.08}] (mm {in}) 0 {0.00}
Total toe-in
(degree) 0°00′±0°09′
Caster angle*2[Tolerance ±1°] 3°02′ 3°05′ 3°08′ 3°10′ 3°12′
Camber angle*2[Tolerance ±1°] −0°19′ −0°20′
Steering axis inclination (Reference value) 11°42′ 11°43′ 11°44′
*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2 : Difference between left and right must not exceed 1°30′.
*1 : Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2 : Difference between left and right must not exceed 1°30′.
02-50–1
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
TECHNICAL DATA
Wheel and tire
Item Specification
Standard tire and wheel
Size 18 × 7 1/2J
Offset (mm {in}) 50 {1.97}
Wheel
Pitch circle diameter (mm {in}) 114.3 {4.50}
Material Aluminum alloy
Size P235/60R18 102H 235/60R18 103H (Mexico spec.)
Air pressure Front 220 {2.2, 32} 230 {2.3, 34} (Mexico spec.)
Tire
(kPa {kgf/cm2, psi}) Rear 220 {2.2, 32} 230 {2.3, 34} (Mexico spec.)
Remaining tread (mm {in}) 1.6 {0.06}
Wheel and tire runout Radial direction 1.5 {0.06} max.
(mm {in}) Lateral direction 2.0 {0.08} max.
Wheel and
tire Adhesive-type*1: 10 {0.35} max.
Wheel imbalance (g {oz})
Knock-type*2: 6 {0.21} max.
Tightening torque (N·m {kgf·m, ft·lbf}) 88.2—117.6 {9.00—11.99, 65.06—86.73}
Temporary spare tire
Size 18 × 4T 16 × 5J
Offset (mm {in}) 40 {1.57} 45 {1.77}
Wheel
Pitch circle diameter (mm {in}) 114.3 {4.50}
Material Steel
Size T155/90D18 103M 205/80R16 100M
Tire Air pressure
420 {4.2, 60} 250 {2.5, 36}
(kPa {kgf/cm2, psi})
Wheel and Wheel and tire runout Radial direction 2.0 {0.08} max.
tire (mm {in}) Lateral direction 2.5 {0.10} max.
Suspension
Item Specification
Front lower arm rotational torque 1.4—2.0 N·m {15—20 kgf·cm, 13—17 in·lbf}
Front stabilizer control link ball joint starting torque 0.2—0.9 N·m {2.1—9.1 kgf·cm, 1.8—7.9 in·lbf}
Rear stabilizer control link ball joint starting torque 0.2—0.8 N·m {2.1—8.1 kgf·cm, 1.8—7.0 in·lbf}
End Of Sie
SERVICE TOOLS
02-60 SERVICE TOOLS
SUSPENSION SST . . . . . . . . . . . . . . . . . 02-60–1
End of Toc
SUSPENSION SST
WM: SUSPENSION
id026000800100
End Of Sie
02-60–1
1871-1U-06B(03-02).fm 1 ページ 2006年3月15日 水曜日 午前11時3分
DRIVELINE/AXLE 03SECTION
Toc of SCT
ON-BOARD DIAGNOSTIC . . . . 03-02 DIFFERENTIAL . . . . . . . . . . . . 03-14
SYMPTOM PROPELLER SHAFT . . . . . . . . 03-15
TROUBLESHOOTING . . . . . . 03-03 TRANSFER . . . . . . . . . . . . . . . 03-16
GENERAL PROCEDURES . . . . 03-10 ALL WHEEL DRIVE (AWD) . . . 03-19 03-02
FRONT AXLE . . . . . . . . . . . . . . 03-11 TECHNICAL DATA . . . . . . . . . . 03-50
REAR AXLE . . . . . . . . . . . . . . . 03-12 SERVICE TOOLS . . . . . . . . . . . 03-60
DRIVE SHAFT . . . . . . . . . . . . . . 03-13
Toc of SCT
03-02 ON-BOARD DIAGNOSTIC
ELECTRONIC AWD CONTROL Clearing DTCs Procedures . . . . . . . . . 03-02–2
SYSTEM WIRING DIAGRAM . . . . . . . . . 03-02–1 DTC Table . . . . . . . . . . . . . . . . . . . . . . 03-02–2
ELECTRONIC AWD CONTROL DTC P1887. . . . . . . . . . . . . . . . . . . . . . . . 03-02–3
SYSTEM ON-BOARD DIAGNOSIS . . . . 03-02–2 DTC P1888. . . . . . . . . . . . . . . . . . . . . . . . 03-02–5
Reading DTCs Procedure . . . . . . . . . . . 03-02–2
End of Toc
ELECTRONIC AWD CONTROL SYSTEM WIRING DIAGRAM
WM: DIFFERENTIAL (FF/FR)
id030200800100
K O
IGNITION SWITCH
I
P
AWD SOLENOID
CAN_H PCM
G
DIFFERENTIAL OIL A
TEMPERATURE
SENSOR C
H
CAN_L
BATTERY OTHER SYSTEMS
CAN DRIVER
(TCM, DSC HU/CM,
INSTRUMENT
N CLUSTER ETC.)
acxuuw00002222
End Of Sie
03-02–1
1871-1U-06B(03-02).fm 2 ページ 2006年3月15日 水曜日 午前11時3分
ON-BOARD DIAGNOSTIC
ELECTRONIC AWD CONTROL SYSTEM ON-BOARD DIAGNOSIS
id030200800200
Reading DTCs Procedure
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (notebook PC)
1. Select the “Toolbox” tab.
2. Select “Self Test”.
3. Select “Module”.
4. Select “4WD”.
• When using the PDS (pocket PC)
1. Select “Module Tests”.
2. Select “4WD”.
DLC-2
3. Select “Self Test”.
acxuuw00001063
3. Verify the DTC according to the directions on the
screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
4. After completion of repairs, clear all DTCs stored in the AWD CM. (See 03-02-2 Clearing DTCs Procedures)
DTC Table
DTC Diagnosis system component Page
P1887 AWD solenoid circuit (See 03-02-3 DTC P1887)
P1888 Differential oil temperature sensor circuit (See 03-02-5 DTC P1888)
U0073 CAN system communication error (See 09-02D-7 DTC TABLE[MULTIPLEX
COMMUNICATION SYSTEM])
U0100 Communication error to PCM (See 09-02D-7 DTC TABLE[MULTIPLEX
COMMUNICATION SYSTEM])
U0101 Communication error to TCM (See 09-02D-7 DTC TABLE[MULTIPLEX
COMMUNICATION SYSTEM])
U0121 Communication error to DSC HU/CM (See 09-02D-7 DTC TABLE[MULTIPLEX
COMMUNICATION SYSTEM])
U0155 Communication error to instrument cluster (See 09-02D-7 DTC TABLE[MULTIPLEX
COMMUNICATION SYSTEM])
End Of Sie
03-02–2
1871-1U-06B(03-02).fm 3 ページ 2006年3月15日 水曜日 午前11時3分
ON-BOARD DIAGNOSTIC
DTC P1887
id030200800300
O B
BATTERY
P A
O M K I G E C A
P N L J H F D B B A
03-02–3
1871-1U-06B(03-02).fm 4 ページ 2006年3月15日 水曜日 午前11時3分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT AWD SOLENOID CONDITION Yes Go to next step.
• Turn ignition key to OFF. No Replace AWD solenoid, then go to Step 7.
• Disconnect AWD solenoid connector.
• Inspect AWD solenoid.
(See 03-19-11 AWD SOLENOID
INSPECTION)
• Is it okay?
2 INSPECT AWD SOLENOID TO AWD CM Yes Go to next step.
(POWER SUPPLY CIRCUIT) FOR OPEN No Repair or replace harness for open circuit between AWD
CIRCUIT CM and AWD solenoid, then go to Step 7.
• Disconnect AWD CM connector.
• Inspect for continuity between AWD CM
terminal O and AWD solenoid terminal B.
• Is there continuity?
3 INSPECT AWD SOLENOID TO AWD CM Yes Repair or replace harness for short to ground between AWD
(POWER SUPPLY CIRCUIT) FOR SHORT TO CM and AWD solenoid, then go to Step 7.
GROUND No Go to next step.
• Inspect for continuity between AWD CM
terminal O and ground.
• Is there continuity?
4 INSPECT AWD SOLENOID TO AWD CM Yes Go to next step.
(GROUND CIRCUIT) FOR OPEN CIRCUIT No Repair or replace harness for open circuit between AWD
• Inspect for continuity between AWD CM CM and AWD solenoid, then go to Step 7.
terminal P and AWD solenoid terminal A.
• Is there continuity?
5 INSPECT AWD SOLENOID TO AWD CM Yes Repair or replace harness for short to ground between AWD
(GROUND CIRCUIT) FOR SHORT TO CM and AWD solenoid, then go to Step 7.
GROUND No Go to next step.
• Inspect for continuity between AWD CM
terminal P and ground.
• Is there continuity?
6 INSPECT AWD CM POWER SUPPLY CIRCUIT Yes Replace AWD CM, then go to Step 7.
FOR OPEN CIRCUIT No Repair or replace harness for open circuit between AWD
• Measure voltage between AWD CM terminal CM and AWD solenoid, then go to next step.
K and ground.
• Is voltage B+?
7 INSPECT FUSE CONDITION Yes Go to next step.
• Turn ignition key to OFF. No Replace fuse, then go to Step 9.
• Is ENG B+ (25A) fuse okay?
8 VERIFY TROUBLESHOOTING COMPLETED Yes Replace AWD CM, then go to next step.
• Make sure to reconnect all disconnected No Go to next step.
connectors.
• Clear DTC from memory.
(See 03-02-2 ELECTRONIC AWD
CONTROL SYSTEM ON-BOARD
DIAGNOSIS)
• Drive vehicle.
• Is the same DTC present?
9 VERIFY AFTER REPAIR PROCEDURE Yes Go to applicable DTC inspection.
• Is there any other DTC present? No Troubleshooting completed.
End Of Sie
03-02–4
1871-1U-06B(03-02).fm 5 ページ 2006年3月15日 水曜日 午前11時3分
ON-BOARD DIAGNOSTIC
DTC P1888
id030200800400
A A
C B
O M K I G E C A
B A
P N L J H F D B
03-02–5
1871-1U-06B(03-02).fm 6 ページ 2006年3月15日 水曜日 午前11時3分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DIFFERENTIAL OIL Yes Go to next step.
TEMPERATURE SENSOR CONDITION No Replace differential oil temperature sensor, then go to Step
• Turn ignition key to OFF. 7.
• Disconnect differential oil temperature
sensor connector.
• Is it okay?
2 INSPECT AWD CM TO DIFFERENTIAL OIL Yes Go to next step.
TEMPERATURE SENSOR FOR OPEN No Repair or replace harness for open circuit between AWD
CIRCUIT CM and differential oil temperature sensor, then go to Step
• Disconnect AWD CM connector. 7.
• Inspect for continuity between AWD CM
terminal A and differential oil temperature
sensor terminal A.
• Is there continuity?
3 INSPECT AWD CM TO DIFFERENTIAL OIL Yes Repair or replace harness for short to power between AWD
TEMPERATURE SENSOR FOR SHORT TO CM and differential oil temperature sensor, then go to Step
POWER 7.
• Inspect voltage between AWD CM terminal A No Go to next step.
and ground.
• Is voltage B+?
4 INSPECT AWD CM TO DIFFERENTIAL OIL Yes Repair or replace harness for short to ground between AWD
TEMPERATURE SENSOR FOR SHORT TO CM and differential oil temperature sensor, then go to Step
GROUND 7.
• Inspect for continuity between AWD CM No Go to next step.
terminal A and ground.
• Is there continuity?
5 INSPECT AWD CM TO DIFFERENTIAL OIL Yes Go to next step.
TEMPERATURE SENSOR FOR OPEN No Repair or replace harness for open circuit between AWD
CIRCUIT CM and differential oil temperature sensor, then go to Step
• Inspect for continuity between AWD CM 7.
terminal C and differential oil temperature
sensor terminal B.
• Is there continuity?
6 INSPECT AWD CM TO DIFFERENTIAL OIL Yes Repair or replace harness for short to power between AWD
TEMPERATURE SENSOR FOR SHORT TO CM and differential oil temperature sensor, then go to next
GROUND step.
• Inspect voltage between AWD CM terminal No Replace AWD CM, then go to next step.
C and ground.
• Is voltage B+?
7 VERIFY TROUBLESHOOTING COMPLETED Yes Replace AWD CM, then go to next step.
• Make sure to reconnect all disconnected No Go to next step.
connectors.
• Clear DTC from memory.
(See 03-02-2 ELECTRONIC AWD
CONTROL SYSTEM ON-BOARD
DIAGNOSIS)
• Drive vehicle.
• Is the same DTC present?
8 VERIFY AFTER REPAIR PROCEDURE Yes Go to applicable DTC inspection.
• Is there any other DTC present? No Troubleshooting completed.
End Of Sie
03-02–6
1871-1U-06B(03-03).fm 1 ページ 2006年3月15日 水曜日 午前11時4分
SYMPTOM TROUBLESHOOTING
03-03 SYMPTOM TROUBLESHOOTING
ELECTRONIC AWD CONTROL NO.1 FREQUENT FRONT WHEEL
SYSTEM WIRING DIAGRAM . . . . . . . . 03-03–1 SLIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-03–3
FOREWORD . . . . . . . . . . . . . . . . . . . . . . 03-03–2 NO.2 TIGHT CORNER BRAKING . . . . . . 03-03–4
SYMPTOM TROUBLESHOOTING . . . . . 03-03–2 NO.3 ABNORMAL NOISE AND/OR
VIBRATION FROM COUPLING
COMPONENT . . . . . . . . . . . . . . . . . . . . . 03-03–5
End of Toc
ELECTRONIC AWD CONTROL SYSTEM WIRING DIAGRAM
WM: DIFFERENTIAL (FF/FR)
id030300800100
03-03
AWD CM ELECTRONIC CONTROL
COUPLING
K O
IGNITION SWITCH
I
P
AWD SOLENOID
CAN_H PCM
G
DIFFERENTIAL OIL A
TEMPERATURE
SENSOR C
H
CAN_L
BATTERY OTHER SYSTEMS
CAN DRIVER
(TCM, DSC HU/CM,
INSTRUMENT
N CLUSTER ETC.)
acxuuw00002222
End Of Sie
03-03–1
1871-1U-06B(03-03).fm 2 ページ 2006年3月15日 水曜日 午前11時4分
SYMPTOM TROUBLESHOOTING
FOREWORD
id030300800200
Troubleshooting completed
acxuuw00001066
End Of Sie
SYMPTOM TROUBLESHOOTING
id030300800300
• Verify the symptoms, and perform troubleshooting according to the appropriate number.
No. Symptom Description
1 Frequent front wheel slip Front wheels slip frequently during acceleration on low-friction road.
2 Brakes seem to be applied during tight cornering while driving very
Tight corner braking effect
slowly on paved road.
3 Abnormal noise and/or vibration from There is abnormal noise and/or vibration from coupling unit during
coupling unit driving.
End Of Sie
03-03–2
1871-1U-06B(03-03).fm 3 ページ 2006年3月15日 水曜日 午前11時4分
SYMPTOM TROUBLESHOOTING
NO.1 FREQUENT FRONT WHEEL SLIP
id030300800400
Warning
• During simulation driving, vehicle stability may decrease extremely and cause an accident. Be
sure to perform the simulation test driving in a safe area.
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY DSC, PCM, AND AWD SYSTEM DTCs Yes Go to applicable DTC inspection.
• Verify DSC, PCM, and AWD system DTCs No Go to next step.
using the M-MDS.
• Are there any DTCs present?
2 VERIFY TIRE AIR PRESSURE Yes Go to next step.
• Inspect tire air pressure. No Adjust tire air pressure, then go to next step.
• Is it within specification?
3 COMPARE WITH SAME MODEL TIRES Yes Go to next step.
• Install tires of the same model. No AWD system is okay.
• Perform simulation driving.
• Does malfunction recur?
4 COMPARE WITH SAME MODEL VEHICLE Yes AWD system is okay.
• Install tires of malfunctioning vehicle to No Go to next step.
another same model vehicle.
• Perform simulation driving.
• Does malfunction recur?
5 INSPECT AWD SOLENOID Yes Inspect harness between AWD solenoid and AWD CM, then
• Inspect AWD solenoid. go to next step.
(See 03-19-11 AWD SOLENOID No Replace coupling component. (See 03-19-4 COUPLING
INSPECTION) COMPONENT REMOVAL/INSTALLATION.)
• Is coupling component solenoid okay?
6 INSPECT WHEEL ALIGNMENT Yes Replace coupling component. (See 03-19-4 COUPLING
• Inspect wheel alignment. COMPONENT REMOVAL/INSTALLATION.)
• Is it okay? No Inspect wheel alignment, and adjust it if necessary.
End Of Sie
03-03–3
1871-1U-06B(03-03).fm 4 ページ 2006年3月15日 水曜日 午前11時4分
SYMPTOM TROUBLESHOOTING
NO.2 TIGHT CORNER BRAKING
id030300800500
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY DSC, PCM, AND AWD SYSTEM DTCS Yes Go to applicable DTC inspection.
• Verify DSC, PCM, and AWD system DTCs No Go to next step.
using the M-MDS.
• Are there any DTCs present?
2 VERIFY TIRE AIR PRESSURE Yes Go to next step.
• Inspect tire air pressure. No Adjust tire air pressure, then go to next step.
• Is it within specification?
3 INSPECT ABS WHEEL-SPEED SENSOR Yes Go to next step.
• Inspect ABS wheel-speed sensor. No Repair or replace malfunctioning part.
• Is it okay?
4 COMPARE WITH SAME MODEL VEHICLE Yes AWD system is okay.
• Perform simulation driving with another same No Go to next step.
model vehicle.
• Does malfunction recur on the same model
vehicle?
5 PERFORM SIMULATION DRIVING WITH AWD Yes Replace coupling component. (See 03-19-4 COUPLING
SOLENOID CONNECTOR DISCONNECTED COMPONENT REMOVAL/INSTALLATION.)
• Turn ignition key OFF. No Go to next step.
• Disconnect AWD solenoid connector.
• Perform simulation driving. (Clear DTC after
simulation driving.)
• Does malfunction recur?
6 INSPECT AWD SOLENOID Yes Inspect harness between AWD solenoid and AWD CM, then
• Inspect AWD solenoid. go to next step.
(See 03-19-11 AWD SOLENOID No Replace coupling component. (See 03-19-4 COUPLING
INSPECTION) COMPONENT REMOVAL/INSTALLATION.)
• Is it okay?
End Of Sie
03-03–4
1871-1U-06B(03-03).fm 5 ページ 2006年3月15日 水曜日 午前11時4分
SYMPTOM TROUBLESHOOTING
NO.3 ABNORMAL NOISE AND/OR VIBRATION FROM COUPLING COMPONENT
id030300800600
Diagnostic procedure
STEP INSPECTION ACTION 03-03
1 VERIFY DSC, PCM, AND AWD SYSTEM DTCS Yes Go to applicable DTC inspection.
• Verify DSC, PCM, and AWD system DTCs No Go to next step.
using the M-MDS.
• Are there any DTCs present?
2 VERIFY INSTALLATION CONDITION OF Yes Go to next step.
VEHICLE PARTS No Repair or replace malfunctioning part.
• Verify installation condition for following:
— Propeller shaft (including bending and
joint operation)
— Center bearing
— Engine mount
— Differential mount
— Hub bearing
— Exhaust system parts
— ABS wheel-speed sensor
• Are they properly installed?
3 DETERMINE IF MALFUNCTION IS CAUSED Yes Reinstall customer’s vehicle tire. Go to next step.
BY REAR DIFFERENTIAL No AWD system is okay.
• Install tires of another brand. Reinstall customer’s vehicle tire.
Note
• When tires of another brand are
installed, the same malfunction can
occur due to conditions different from
customer explanation. Be careful not
to confuse it with customer complaint.
End Of Sie
03-03–5
1871-1U-06B(03-10).fm 1 ページ 2006年3月15日 水曜日 午前11時4分
GENERAL PROCEDURES
03-10 GENERAL PROCEDURES
GENERAL PROCEDURES Suspension Links
(FRONT AND REAR AXLES) . . . . . . . 03-10–1 Removal/Installation . . . . . . . . . . . . . . 03-10–1
Wheel and Tire Installation . . . . . . . . . 03-10–1 Connector Disconnection . . . . . . . . . . . 03-10–1
Electronic AWD Control System
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . 03-10–1
End of Toc
GENERAL PROCEDURES (FRONT AND REAR AXLES)
WM: DRIVELINE/AXLE
id031000800100
Wheel and Tire Installation
1. When installing the wheels and tires, tighten the 03-10
wheel nuts in a criss-cross pattern to the following
tightening torque.
Tightening torque 1
88.2— 117.6 N·m {9.00— 11.99 kgf·m, 4 3
65.06— 86.73 ft·lbf}
2 5
acxuuw00000002
Connector Disconnection
1. Disconnect the negative battery cable before performing any work that requires handling of connectors. (See
01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].)
03-10–1
1871-1U-06B(03-11).fm 1 ページ 2006年3月15日 水曜日 午前11時5分
FRONT AXLE
03-11 FRONT AXLE
FRONT AXLE LOCATION INDEX. . . . . . 03-11–1 Brake Caliper Removal Note . . . . . . . . . 03-11–4
FRONT WHEEL HUB BOLT Wheel Hub Removal Note. . . . . . . . . . . 03-11–5
REPLACEMENT. . . . . . . . . . . . . . . . . . 03-11–2 Wheel Bearing Removal Note . . . . . . . . 03-11–5
WHEEL HUB, STEERING Dust Cover Removal Note. . . . . . . . . . . 03-11–5
KNUCKLE INSPECTION. . . . . . . . . . . . 03-11–2 Wheel Hub Bolt Removal Note . . . . . . . 03-11–6
Wheel Bearing Excessive Play Wheel Hub Bolt Installation Note . . . . . 03-11–6
Inspection. . . . . . . . . . . . . . . . . . . . . . 03-11–2 Dust Cover Installation Note . . . . . . . . . 03-11–6
WHEEL HUB, STEERING KNUCKLE Wheel Bearing Installation Note . . . . . . 03-11–7
REMOVAL/INSTALLATION. . . . . . . . . . 03-11–3 Wheel Hub Installation Note . . . . . . . . . 03-11–7
Locknut Removal Note . . . . . . . . . . . . . 03-11–4 Locknut Installation Note . . . . . . . . . . . . 03-11–7
03-11
End of Toc
FRONT AXLE LOCATION INDEX
WM: FRONT AXLE
id031100800100
ampjjw00003178
End Of Sie
03-11–1
1871-1U-06B(03-11).fm 2 ページ 2006年3月15日 水曜日 午前11時5分
FRONT AXLE
FRONT WHEEL HUB BOLT REPLACEMENT
id031100800200
1. Remove the brake calliper component from the steering knuckle and suspend it out of the way using a cable.
2. Remove the disc plate.
3. Tap the dust cover (the part shown in the figure)
with a chisel lightly and bend the processing point
back to the steering knuckle side.
acxuuw00001094
49 T028 3A0
acxuuw00001095
WHEEL NUT
BRASS BAR WHEEL NUT WASHER
acxuuw00001096
End Of Sie
acxuuw00001097
03-11–2
1871-1U-06B(03-11).fm 3 ページ 2006年3月15日 水曜日 午前11時5分
FRONT AXLE
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION
id031100800400
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing
the following procedures, disconnect the ABS wheel-speed sensor connector (axle side) and fix
the wiring harness to an appropriate place where it will not be pulled by mistake while servicing
the vehicle.
1. Remove the front ABS wheel-speed sensor. (See 04-15-11 FRONT ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal. 03-11
4. After installation, inspect the front wheel alignment and adjust it if necessary. (See 02-11-2 FRONT WHEEL
ALIGNMENT.)
14 SST R
163.0—194.0
{16.63—19.78,
13
120.3—143.0}
7 R
SST
12
R
11 SST
R 10
1
9
47.0—59.0
C {4.80—6.01, R 15
34.7—43.5}
A
43.1—58.8
C {4.40—5.99,
6 31.8—43.3}
SST 4
5
9.8—14.7 N·m
{100—149 kgf·cm,
B
87—129 in·lbf}
42.3—60.8 B
{4.32—6.19,
31.2—44.8}
2 R
8 235.2—274.4
107.8—127.4 A {23.99—27.98,
{11.00—12.99, 173.5—202.3}
79.51—93.96}
3
N·m {kgf·m, ft·lbf}
acxuuw00001113
03-11–3
1871-1U-06B(03-11).fm 4 ページ 2006年3月15日 水曜日 午前11時5分
FRONT AXLE
11 Retaining ring 14 Steering knuckle
12 Wheel bearing 15 Wheel hub bolt
(See 03-11-5 Wheel Bearing Removal Note.) (See 03-11-6 Wheel Hub Bolt Removal Note.)
(See 03-11-7 Wheel Bearing Installation Note.) (See 03-11-6 Wheel Hub Bolt Installation Note.)
13 Dust cover
(See 03-11-5 Dust Cover Removal Note.)
(See 03-11-6 Dust Cover Installation Note.)
acxuuw00001114
acxuuw00001115
acxuuw00001116
03-11–4
1871-1U-06B(03-11).fm 5 ページ 2006年3月15日 水曜日 午前11時5分
FRONT AXLE
Wheel Hub Removal Note
1. Remove the wheel hub using the SSTs.
Substitution SST 49 G033 102 49 G033 105
• 49 G033 105
Outer diameter: 37— 43 mm {1.5— 1.6 in}
49 F026 103
acxuuw00001117 03-11
2. If the bearing inner race remains on the front
wheel hub component, grind a section of the
bearing inner race until approx. 0.5 mm {0.02 in}
remains. Then remove it using a chisel.
acxuuw00001118
49 F026103
acxuuw00001119
Note
• The dust cover does not need to be removed unless it is being replaced.
MARKING
acxuuw00001120
03-11–5
1871-1U-06B(03-11).fm 6 ページ 2006年3月15日 水曜日 午前11時5分
FRONT AXLE
2. Remove the dust cover using a chisel.
acxuuw00001121
Note
• The hub bolts do not need to be removed unless they are being replaced.
acxuuw00001122
acxuuw00001123
acxuuw00001124
03-11–6
1871-1U-06B(03-11).fm 7 ページ 2006年3月15日 水曜日 午前11時5分
FRONT AXLE
3. Install the new dust cover using the SSTs.
Substitution SST STEEL PLATE
• 49 G033 107A 49 G033 107A
Inner diameter: 98— 108 mm {3.9— 4.2 in}
Tube with board thickness 3 mm {0.2 in} or
more
• 49 F027 009
Outer diameter: 77— 82 mm {3.1— 3.2 in}
49 F027 009
acxuuw00001125
03-11
Wheel Bearing Installation Note
1. Install the new wheel bearing using the SSTs.
Substitution SST 49 F027 003
• 49 F027 004
Outer diameter: 78— 83 mm {3.1— 3.2 in} 49 F027 004
• 49 F027 009
Outer diameter: 77— 82 mm {3.1— 3.2 in}
49 F027 009
acxuuw00001126
49 B025 004
acxuuw00001127
acxuuw00001576
03-11–7
1871-1U-06B(03-12).fm 1 ページ 2006年3月15日 水曜日 午前11時5分
REAR AXLE
03-12 REAR AXLE
REAR AXLE LOCATION INDEX . . . . . . . 03-12–1 WHEEL HUB COMPONENT
REAR WHEEL HUB BOLT REMOVAL/INSTALLATION[2WD]. . . . . 03-12–3
REPLACEMENT . . . . . . . . . . . . . . . . . . 03-12–2 Brake Caliper Component
WHEEL HUB COMPONENT Removal Note . . . . . . . . . . . . . . . . . . . 03-12–4
INSPECTION . . . . . . . . . . . . . . . . . . . . 03-12–2 Wheel Hub Bolt Removal Note . . . . . . . 03-12–4
Wheel Bearing Excessive Play Wheel Hub Bolt Installation Note . . . . . 03-12–4
Inspection. . . . . . . . . . . . . . . . . . . . . . 03-12–2 WHEEL HUB COMPONENT
REMOVAL/INSTALLATION[AWD] . . . . . 03-12–5
End of Toc
03-12
REAR AXLE LOCATION INDEX
WM: REAR AXLE
id031200800100
AWD
2WD
2 1
1
acxuuw00001132
End Of Sie
03-12–1
1871-1U-06B(03-12).fm 2 ページ 2006年3月15日 水曜日 午前11時5分
REAR AXLE
REAR WHEEL HUB BOLT REPLACEMENT
id031200800200
1. Remove the brake calliper component and suspend it out of the way using a cable.
2. Remove the disc plate.
3. Remove the parking brake shoe.
4. Remove the wheel hub bolt using the SST as
shown in the figure.
5. Place a new wheel hub bolt in the wheel hub.
49 T028 3A0
acxuuw00001133
WHEEL NUT
BRASS BAR WHEEL NUT WASHER
acxuuw00001134
End Of Sie
B3E0312W002
03-12–2
1871-1U-06B(03-12).fm 3 ページ 2006年3月15日 水曜日 午前11時5分
REAR AXLE
WHEEL HUB COMPONENT REMOVAL/INSTALLATION[2WD]
id0312008004a1
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing
the following procedures, disconnect the ABS wheel-speed sensor connector (body side) and fix
the wiring harness to an appropriate place where it will not be pulled by mistake while servicing
the vehicle.
1. Remove the rear ABS wheel-speed sensor. (See 04-15-13 REAR ABS WHEEL-SPEED SENSOR REMOVAL/
INSTALLATION[2WD].)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal. 03-12
2
98—120 78.4—101.9
{10.0—12.2, {8.00—10.39,
72.3—88.5} 57.83—75.15} 3
1
6
7 9.8—14.7 N·m
R 5 {100—149 kgf·cm,
87—130 in·lbf}
4
N·m {kgf·m, ft·lbf}
acxuuw00001943
03-12–3
1871-1U-06B(03-12).fm 4 ページ 2006年3月15日 水曜日 午前11時5分
REAR AXLE
Brake Caliper Component Removal Note
1. Remove the brake caliper component from the trailing link and suspend it out of the way using a cable.
Note
• The wheel hub bolts do not need to be removed unless they are being replaced.
acxuuw00001145
acxuuw00001146
03-12–4
1871-1U-06B(03-12).fm 5 ページ 2006年3月15日 水曜日 午前11時5分
REAR AXLE
WHEEL HUB COMPONENT REMOVAL/INSTALLATION[AWD]
id0312008004a3
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing
the following procedures, disconnect the ABS wheel-speed sensor connector (body side) and fix
the wiring harness to an appropriate place where it will not be pulled by mistake while servicing
the vehicle.
1. Remove the rear ABS wheel-speed sensor. (See 04-15-14 REAR ABS WHEEL-SPEED SENSOR
INSPECTION[AWD].)
2. Remove the rear stabilizer. (See 02-14-11 REAR STABILIZER REMOVAL/INSTALLATION.)
3. Remove the rear coil spring. (See 02-14-6 REAR COIL SPRING REMOVAL/INSTALLATION.) 03-12
4. Remove the trailing link. (See 02-14-15 TRAILING LINK REMOVAL/INSTALLATION[AWD].)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
75.5—102
{7.70—10.4,
55.7—75.2}
98—120
{10.0—12.2, 78.4—101.9
72.3—88.5} {8.00—10.39,
57.83—75.15}
75.5—102
{7.70—10.4,
55.7—75.2} 2
97.7—132.3
{9.97—13.49,
3
R 1 R
72.06—97.57}
235—275
{24.0—28.0,
174—202}
End Of Sie
03-12–5
1871-1U-06B(03-13).fm 1 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
03-13 DRIVE SHAFT
DRIVE SHAFT LOCATION INDEX . . . . . 03-13–2 FRONT DRIVE SHAFT
JOINT SHAFT PRE-INSPECTION DISASSEMBLY/ASSEMBLY . . . . . . . . . 03-13–15
[2WD]. . . . . . . . . . . . . . . . . . . . . . . . . . . 03-13–2 Boot Band (Wheel Side)
JOINT SHAFT Disassembly Note . . . . . . . . . . . . . . . . 03-13–16
REMOVAL/INSTALLATION[2WD] . . . . 03-13–3 Boot Band (Transaxle Side)
Joint Shaft Removal Note . . . . . . . . . . 03-13–4 Disassembly Note . . . . . . . . . . . . . . . . 03-13–16
Clip Installation Note . . . . . . . . . . . . . . 03-13–4 Outer Ring Disassembly Note . . . . . . . . 03-13–16
JOINT SHAFT Snap Ring, Tripod Joint
REMOVAL/INSTALLATION[AWD] . . . . 03-13–4 Disassembly Note . . . . . . . . . . . . . . . . 03-13–17
Joint Shaft Removal Note . . . . . . . . . . 03-13–5 Boot Disassembly Note . . . . . . . . . . . . . 03-13–17
Clip Installation Note . . . . . . . . . . . . . . 03-13–5 Boot Assembly Note . . . . . . . . . . . . . . . 03-13–17 03-13
JOINT SHAFT DISASSEMBLY[2WD]. . . 03-13–6 Tripod Joint, Snap Ring
Dust Seal (Axle Side) Assembly Note . . . . . . . . . . . . . . . . . . 03-13–18
Disassembly Note . . . . . . . . . . . . . . . 03-13–6 Outer Ring Assembly Note . . . . . . . . . . 03-13–18
Joint Shaft Disassembly Note . . . . . . . 03-13–6 Boot Band (Transaxle Side)
Dust Seal (Differential Side) Assembly Note . . . . . . . . . . . . . . . . . . 03-13–18
Disassembly Note . . . . . . . . . . . . . . . 03-13–7 Boot Band (Wheel Side)
Bearing Disassembly Note. . . . . . . . . . 03-13–7 Assembly Note . . . . . . . . . . . . . . . . . . 03-13–19
JOINT SHAFT DISASSEMBLY[AWD] . . 03-13–7 REAR DRIVE SHAFT
Dust Seal Disassembly Note . . . . . . . . 03-13–7 PRE-INSPECTION . . . . . . . . . . . . . . . . . 03-13–19
Bearing Disassembly Note. . . . . . . . . . 03-13–8 REAR DRIVE SHAFT
JOINT SHAFT ASSEMBLY[2WD]. . . . . . 03-13–8 REMOVAL/INSTALLATION . . . . . . . . . . 03-13–20
Bearing Assembly Note . . . . . . . . . . . . 03-13–8 Rear Drive Shaft Removal Note . . . . . . 03-13–20
Dust Seal (Differential Side) Clip Installation Note . . . . . . . . . . . . . . . 03-13–21
Assembly Note . . . . . . . . . . . . . . . . . . 03-13–9 REAR DRIVE SHAFT
Dust Seal (Axle Side) DISASSEMBLY/ASSEMBLY . . . . . . . . . 03-13–21
Assembly Note . . . . . . . . . . . . . . . . . . 03-13–9 Boot Band (Wheel Side)
Joint Shaft Assembly Note . . . . . . . . . . 03-13–9 Disassembly Note . . . . . . . . . . . . . . . . 03-13–22
JOINT SHAFT ASSEMBLY[AWD] . . . . . 03-13–10 Boot Band (Differential Side)
Bearing Assembly Note . . . . . . . . . . . . 03-13–10 Disassembly Note . . . . . . . . . . . . . . . . 03-13–22
Joint Shaft Assembly Note . . . . . . . . . . 03-13–10 Clip Disassembly Note . . . . . . . . . . . . . 03-13–22
Dust Seal Assembly Note . . . . . . . . . . 03-13–11 Snap Ring Disassembly Note . . . . . . . . 03-13–22
FRONT DRIVE SHAFT Balls, Inner Ring, Cage
PRE-INSPECTION . . . . . . . . . . . . . . . . 03-13–11 Disassembly Note . . . . . . . . . . . . . . . . 03-13–23
FRONT DRIVE SHAFT Boot Assembly Note . . . . . . . . . . . . . . . 03-13–23
REMOVAL/INSTALLATION. . . . . . . . . . 03-13–12 Cage, Inner Ring, Balls, Snap Ring
Locknut Removal Note . . . . . . . . . . . . . 03-13–13 Assembly Note . . . . . . . . . . . . . . . . . . 03-13–23
Front Drive Shaft Removal Note . . . . . 03-13–13 Outer Ring, Clip Assembly Note . . . . . . 03-13–24
Clip Installation Note . . . . . . . . . . . . . . 03-13–13 Boot Band (Differential Side)
Front Drive Shaft Installation Note . . . . 03-13–14 Assembly Note . . . . . . . . . . . . . . . . . . 03-13–24
Locknut Installation Note . . . . . . . . . . . 03-13–14 Boot Band (Wheel Side)
Assembly Note . . . . . . . . . . . . . . . . . . 03-13–25
End of Toc
WM: FRONT DRIVE SHAFT
03-13–1
1871-1U-06B(03-13).fm 2 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
DRIVE SHAFT LOCATION INDEX
id031300800100
2WD
3
2
AWD
2
acxuuw00001153
End Of Sie
JOINT SHAFT PRE-INSPECTION[2WD]
WM: JOINT SHAFT
id0313008008a3
1. Verify that the joint shaft is not twisted or cracked.
• Replace it as necessary.
03-13–2
1871-1U-06B(03-13).fm 3 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
2. Turn the joint shaft by hand and verify that the
bearing rotates smoothly and freely.
• Replace it as necessary.
End Of Sie
acxuuw00001164
JOINT SHAFT REMOVAL/INSTALLATION[2WD]
id0313008009a3 03-13
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.
1. Remove the side cover and under cover.
2. Remove the front ABS wheel-speed sensor. (See 04-15-11 FRONT ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION.)
3. Remove the crankshaft position (CKP) sensor. (See 01-40-42 CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION[L3 WITH TC].)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
42—62
{4.3—6.3, 31—45}
4
47.0—59.0
{4.80—6.01, R A
34.7—43.5}
2
5
R
1 SST
A
43.1—58.8
{4.40—5.99,
31.8—43.3}
42.3—60.1
3 {4.32—6.12,
31.2—44.3}
N·m {kgf·m, ft·lbf}
acxuuw00001184
03-13–3
1871-1U-06B(03-13).fm 4 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Joint Shaft Removal Note
1. Separate the right side drive shaft from the joint
shaft by tapping on a brass bar inserted between
them.
2. Remove the bolts.
3. Pull the joint shaft straight out.
Caution
• The sharp edges of the joint shaft can
slice or puncture the oil seal. Be careful
when removing the joint shaft from the
transaxle.
acxuuw00001185
End Of Sie
OUTER
DIAMETER
acxuuw00001186
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.
03-13–4
1871-1U-06B(03-13).fm 5 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
19—27
{1.93—2.75, 14.1—19.9}
2 4
47.0—59.0
{4.80—6.01,
34.7—43.5} R
A
SST 5 R
1
03-13
43.1—58.8
{4.40—5.99,
31.8—43.3}
A
3 42.3—60.1
{4.32—6.12,
31.2—44.3}
N·m {kgf·m, ft·lbf}
acxuuw00001187
Caution
• The sharp edges of the joint shaft can
slice or puncture the oil seal. Be careful
when removing the joint shaft from the
transaxle.
acxuuw00001188
03-13–5
1871-1U-06B(03-13).fm 6 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
2. After installation, measure the outer diameter. If it
exceeds the specification, repeat Step 1 using a
new clip.
CLIP
Outer diameter specification
34.0 mm {1.34 in} max. OPENING
End Of Sie
OUTER
DIAMETER
acxuuw00001189
SST
7 SST
6
2
1
3
5
4
acxuuw00001302
ampjjw00003305
03-13–6
1871-1U-06B(03-13).fm 7 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Dust Seal (Differential Side) Disassembly Note
1. Remove the dust seal using a flathead screwdriver.
acxuuw00001303
3
5
6
1
acxuuw00001353
03-13–7
1871-1U-06B(03-13).fm 8 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Bearing Disassembly Note
1. Remove the bearing from the joint shaft using a
press.
End Of Sie
BEARING
acxuuw00001354
R GREASE
SST
2 SST R
4
7.8—10.8 N·m
{80—110 kgf·cm, 69.1—95.5 in·lbf}
8
5 7 SST
R 6
SST
3
R R
1
GREASE
acxuuw00001348
acxuuw00001349
03-13–8
1871-1U-06B(03-13).fm 9 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Dust Seal (Differential Side) Assembly Note
1. Apply grease to the new dust seal lip.
2. Install the dust seal (differential side) using a
press and the SSTs. 49 G030 797
Substitution SST
• 49 B025 004
Outer diameter: 58— 59.8 mm {2.2— 2.3 in}
or less 49 B025 004
Inner diameter: 53 mm {2.1 in} or more
Inner depth: 7.5 mm {0.30 in} or more
03-13
acxuuw00001349
acxuuw00001351
03-13–9
1871-1U-06B(03-13).fm 10 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
JOINT SHAFT ASSEMBLY[AWD]
id0313008011a5
1. Assemble in the order indicated in the table. .
R
3 R
2 SST
6
R 5
SST R
acxuuw00001355
Note
• When the bearing is not installed to the
bracket by hand, install it using the SST.
acxuuw00001356
acxuuw00001357
03-13–10
1871-1U-06B(03-13).fm 11 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Dust Seal Assembly Note
1. Apply grease to the new dust seal lip.
2. Install the new dust seal using a press and the
SSTs.
Substitution SST
• 49 G028 203
Outer diameter: 64 mm {2.5 in} or more
Inner diameter: 57.6— 59.0 mm {2.27— 2.32 49 G028 203
in}
Inner depth: 38.5 mm {1.52 in} or more
End Of Sie
WM: DRIVE SHAFT
03-13
acxuuw00001358
A6E0313W033
03-13–11
1871-1U-06B(03-13).fm 12 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
FRONT DRIVE SHAFT REMOVAL/INSTALLATION
id031300800300
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.
6 R
5 R
47.0—59.0
{4.80—6.01,
34.7—43.5}
SST
2
1 R
R 6 235.2—274.4
{23.99—27.98,
173.5—202.3}
A
3
42.3—60.1 4 43.1—58.8
{4.32—6.12, {4.40—5.99,
31.2—44.3} 31.8—43.3}
N·m {kgf·m, ft·lbf}
acxuuw00001222
03-13–12
1871-1U-06B(03-13).fm 13 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Locknut Removal Note
1. Lock the hub by applying the brakes.
2. Knock the crimped portion of the locknut outward
using a small chisel and a hammer.
3. Remove the locknut.
03-13
acxuuw00001114
Caution
• The sharp edges of the drive shaft can
slice or puncture the oil seal. Be careful
when removing the drive shaft from the
transaxle.
acxuuw00001115
acxuuw00001223
acxuuw00001224
03-13–13
1871-1U-06B(03-13).fm 14 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
2. After installation, measure the outer diameter. If it
exceeds the specification, repeat Steps 1— 2
using a new clip.
CLIP
acxuuw00001225
Caution
• The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful when installing the
drive shaft to the transaxle.
• The oil seals are damaged easily if this
procedure is not done correctly.
acxuuw00001226
Left side
1. Insert the drive shaft into the wheel hub.
2. Apply transaxle oil to the oil seal lip.
3. Push the drive shaft into the transaxle.
4. After installation, pull the transaxle side outer ring forward to confirm that the drive shaft is securely held by the
clip.
Right side
1. Insert the drive shaft into the wheel hub.
2. Insert the drive shaft into the joint shaft.
3. After installation, pull the transaxle side outer ring forward to confirm that the drive shaft is securely held by the
clip.
acxuuw00001128
03-13–14
1871-1U-06B(03-13).fm 15 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY
id031300800400
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
SST 1
R
GREASE
8 R
GREASE
1 SST R
R 2
R 03-13
9
7 RIGHT SIDE
GREASE
R 8
2
R
5 R 6
3
4
acxuuw00001241
03-13–15
1871-1U-06B(03-13).fm 16 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Boot Band (Wheel Side) Disassembly Note
Note
• The boot band does not need to be removed unless it is being replaced.
acxuuw00001242
acxuuw00001243
acxuuw00001244
acxuuw00001245
03-13–16
1871-1U-06B(03-13).fm 17 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Snap Ring, Tripod Joint Disassembly Note
1. Mark the shaft and tripod joint for proper assembly.
2. Remove the snap ring using snap-ring pliers.
3. Remove the tripod joint from the shaft.
Caution
• Do not tap the tripod joint with a hammer.
MARK
03-13
acxuuw00001246
Note
• The wheel side boot does not need to be removed unless replacing it or the ball joint and shaft
component.
• Do not strip the tape until the boot is assembled.
TAPE
acxuuw00001247
Note
• The wheel side and transaxle side boots are different.
Caution
• Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.
Grease amount
110— 130 g {3.89— 4.58 oz}
2. With the splines of the shaft still wrapped in tape from disassembly, install the boot.
3. Remove the tape.
03-13–17
1871-1U-06B(03-13).fm 18 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Tripod Joint, Snap Ring Assembly Note
1. Align the marks and install the tripod joint using a
bar and a hammer.
2. Install the new snap ring using snap-ring pliers. MARK
Caution
• Be sure the snap ring engages correctly
in the groove of the shaft.
acxuuw00001248
Caution
• Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.
Grease amount
240— 260 g {8.48— 9.17 oz}
Caution
• Do not let grease leak.
• Do not damage the boot.
acxuuw00001249
Caution
• Install the band into the groove securely.
acxuuw00001250
03-13–18
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
DRIVE SHAFT
Boot Band (Wheel Side) Assembly Note
1. Adjust clearance A by turning the adjusting bolt of
the SST.
49 T025 001
acxuuw00001251 03-13
2. Crimp the wheel side small boot band using the
SST. Verify that clearance B is within the B
specification.
• If clearance B is more than the specification,
reduce clearance A of the SST and crimp the
boot again.
• If clearance B is less than the specification, 49 T025 001
replace the boot band, increase clearance A
of the SST, and crimp the new boot.
Clearance B
2.4— 2.8 mm {0.095— 0.110 in}
acxuuw00001252
Clearance A
3.2 mm {0.13 in}
6. Crimp the wheel side big boot band using the SST.
7. Verify that clearance B is within the specification.
• If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
• If clearance B is less than the specification, replace the boot band, increase clearance A of the SST and
crimp the new boot.
Clearance B
2.4— 2.8 mm {0.095— 0.110 in}
8. Verify that the boot band does not protrude from the boot band installation area.
• If it does, replace the boot band and repeat Steps 7 and 8.
End Of Sie
REAR DRIVE SHAFT PRE-INSPECTION
WM: REAR DRIVE SHAFT
id031300800500
1. Inspect each connecting part for looseness.
• Tighten or replace parts if necessary.
2. Inspect the dust boot on the drive shaft for cracks,
damage, leaking grease, and looseness in the
boot band.
3. Inspect the drive shaft for bends, cracks, and
wear in the joints or splines.
• Repair or replace the drive shaft or boot band
if necessary.
End Of Sie
A6J63172101
03-13–19
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
DRIVE SHAFT
REAR DRIVE SHAFT REMOVAL/INSTALLATION
id031300800600
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (wheel side) and fix it to an
appropriate place where the sensor will not be pulled by mistake while the vehicle is being
serviced.
1. Drain the rear differential oil into a container. (See 03-14-2 DIFFERENTIAL OIL REPLACEMENT.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. After installation, add the specified rear differential oil. (See 03-14-2 DIFFERENTIAL OIL REPLACEMENT.)
5. Inspect the rear wheel alignment and adjust it if necessary. (See 02-11-4 REAR WHEEL ALIGNMENT.)
78.4—101.9
{8.0—10.3,
57.9—75.1} 75.5—102
75.5—102
{7.70—10.4, {7.70—10.4,
3 R 55.7—75.2}
55.7—75.2}
2 SST
97.7—132.3 R
{10.0—13.4, 75.5—102
{7.70—10.4, 235—275
72.1—97.5} {23.97—28.0,
55.7—75.2}
174—202.}
N·m {kgf·m, ft·lbf}
acxuuw00002554
49 B025 010
acxuuw00002550
DRIVE SHAFT
Clip Installation Note
1. Install a new clip onto the joint shaft with the opening facing upward. Ensure that the diameter of the clip does
not exceed the specification on installation.
2. After installation, measure the outer diameter. If it
exceeds the specification, repeat Steps 1— 2
using a new clip.
CLIP
End Of Sie
OUTER
DIAMETER
03-13
acxuuw00001259
R
3
7
6
R
2
4
9 R
5 2
R
8 R
GREASE
1
9
R
1
10
GREASE
acxuuw00001295
03-13–21
1871-1U-06B(03-13).fm 22 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Boot Band (Wheel Side) Disassembly Note
Note
• The boot band does not need to be removed unless it is being replaced.
acxuuw00001242
acxuuw00001243
Caution
• Mark with paint; do not use a punch.
acxuuw00001296
Caution
• Mark with paint; do not use a punch.
MARK
acxuuw00001297
03-13–22
1871-1U-06B(03-13).fm 23 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Balls, Inner Ring, Cage Disassembly Note
1. Mark the inner ring and cage for proper reassembly.
Caution
• Mark with paint; do not use a punch.
03-13
acxuuw00001298
Note
• The wheel side and differential side boots are different.
Caution
• Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.
Grease amount
70— 90 g {2.48— 3.17 oz}
2. With the splines of the shaft wrapped in tape, install the boot.
3. Remove the tape.
Caution
• Install the cage so that the major
diameter is at the same side as the snap
ring groove. If incorrectly installed, the
drive shaft may become disengaged.
SNAP RING INNER
2. Align the marks and install the inner ring to the GROOVE RING MARK
shaft.
3. Install a new snap ring.
acxuuw00001299
03-13–23
1871-1U-06B(03-13).fm 24 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Outer Ring, Clip Assembly Note
1. Fill the outer ring and boot (differential side) with the specified grease.
Caution
• Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.
Grease amount
90— 110 g {3.18— 3.88 oz}
acxuuw00001296
Caution
• Do not let grease leak.
• Do not damage the boot.
Caution
• Install the band into the groove securely.
acxuuw00001250
03-13–24
1871-1U-06B(03-13).fm 25 ページ 2006年3月15日 水曜日 午前11時6分
DRIVE SHAFT
Boot Band (Wheel Side) Assembly Note
1. Adjust clearance A by turning the adjusting bolt of
the SST.
49 T025 001
acxuuw00001251 03-13
2. Crimp the wheel side small boot band using the
SST. Verify that clearance B is within the B
specification.
• If clearance B is more than the specification,
reduce clearance A of the SST and crimp the
boot again.
• If clearance B is less than the specification, 49 T025 001
replace the boot band, increase clearance A
of the SST, and crimp the new boot.
Clearance B
2.4— 2.8 mm {0.095— 0.110 in}
acxuuw00001252
Clearance A
3.2 mm {0.13 in}
6. Crimp the wheel side big boot band using the SST.
7. Verify that clearance B is within the specification.
• If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
• If clearance B is less than the specification, replace the boot band, increase clearance A of the SST and
crimp the new boot.
Clearance B
2.4— 2.8 mm {0.095— 0.110 in}
8. Verify that the boot band does not protrude from the boot band installation area.
• If it does, replace the boot band and repeat Steps 7 and 8.
End Of Sie
03-13–25
1871-1U-06B(03-14).fm 1 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
03-14 DIFFERENTIAL
REAR DIFFERENTIAL Bearing Inner Race (Rear Bearing)
LOCATION INDEX. . . . . . . . . . . . . . . . . 03-14–1 Disassembly Note . . . . . . . . . . . . . . . 03-14–8
DIFFERENTIAL OIL INSPECTION . . . . . 03-14–2 Bearing Outer Race
DIFFERENTIAL OIL REPLACEMENT . . 03-14–2 Disassembly Note . . . . . . . . . . . . . . . 03-14–8
OIL SEAL (SIDE GEAR) Ring Gear Disassembly Note . . . . . . . . 03-14–9
REPLACEMENT . . . . . . . . . . . . . . . . . . 03-14–2 Side Bearing Inner Race
OIL SEAL (COMPANION FLANGE) Disassembly Note . . . . . . . . . . . . . . . . 03-14–9
REPLACEMENT. . . . . . . . . . . . . . . . . . 03-14–3 REAR DIFFERENTIAL ASSEMBLY. . . . . 03-14–10
REAR DIFFERENTIAL Side Bearing Inner Race
REMOVAL/INSTALLATION. . . . . . . . . . 03-14–5 Assembly Note . . . . . . . . . . . . . . . . . . 03-14–11
REAR DIFFERENTIAL Thrust washer Assembly Note . . . . . . . 03-14–11 03-14
DISASSEMBLY . . . . . . . . . . . . . . . . . . . 03-14–6 Ring Gear Assembly Note. . . . . . . . . . . 03-14–12
Rear Cover Disassembly Note . . . . . . . 03-14–7 Bearing Outer Race Assembly Note . . . 03-14–12
Bearing Cap Disassembly Note . . . . . . 03-14–7 Spacer, Bearing Inner Race
Rear Differential Component Assembly Note . . . . . . . . . . . . . . . . . . 03-14–13
Disassembly Note . . . . . . . . . . . . . . . 03-14–7 Locknut Assembly Note. . . . . . . . . . . . . 03-14–15
Locknut Disassembly Note. . . . . . . . . . 03-14–8 Adjusting Shim Assembly Note . . . . . . . 03-14–15
Drive Pinion Disassembly Note . . . . . . 03-14–8 Bearing Cap Assembly Note . . . . . . . . . 03-14–17
Rear Cover Assembly Note . . . . . . . . . . 03-14–18
Oil Seal Assembly Note . . . . . . . . . . . . 03-14–18
End of Toc
REAR DIFFERENTIAL LOCATION INDEX
WM: DIFFERENTIAL (FF/FR)
id031400800300
acxuuw00001575
End Of Sie
03-14–1
1871-1U-06B(03-14).fm 2 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
DIFFERENTIAL OIL INSPECTION
id031400800100
1. Place the vehicle on level ground.
2. Remove the filler plug and washer.
3. Verify that the oil is at the brim of the filler plug FILLER PLUG
hole.
4. If it is low, add the specified oil.
5. Install a new washer and the filler plug, and
tighten.
Tightening torque
39.2— 53.9 N·m {4.0— 5.4 kgf·m, 29.0— 39.7
ft·lbf}
Tightening torque
39.2— 53.9 N·m {4.0— 5.4 kgf·m, 29.0— 39.7
ft·lbf}
5. Add the specified differential oil from the filler plug DRAIN PLUG
until the level reaches the brim of the plug hole.
E6U314ZWC010
Tightening torque
39.2— 53.9 N·m {4.0— 5.4 kgf·m, 29.0— 39.7 ft·lbf}
End Of Sie
OIL SEAL (SIDE GEAR) REPLACEMENT
id031400800700
1. Remove the drain plug and the drain differential oil into a container.
2. Install a new washer and the drain plug, and tighten.
3. Remove the rear drive shaft. (See 03-13-20 REAR DRIVE SHAFT REMOVAL/INSTALLATION.)
4. Remove the clip from the drive shaft.
Caution
• Wrap the end of a screwdriver with cloth to prevent scratches to the inside of the differential
casing.
03-14–2
1871-1U-06B(03-14).fm 3 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
5. Remove the oil seal from the differential casing
using a screwdriver.
6. Apply differential oil to the new oil seal lip.
acxuuw00001378
03-14
7. Install the new oil seal to the differential carrier
using the SSTs.
Substitution SST
• 49 G030 796
Outer diameter: 56— 60 mm {2.21— 2.36 in}
Inner diameter: 49.8 mm {2.0 in} or more
Inner depth: 8.7 mm {0.34 in} or more
8. After installing the new clip onto the drive shaft,
insert the drive shaft into the differential. (See 03-
13-20 REAR DRIVE SHAFT REMOVAL/
49 G030 796
INSTALLATION.) 49 G030 797
9. Verify that the drive shaft cannot be pulled out.
acxuuw00001379
10. Add the specified differential oil.
11. After adding the oil, perform an oil level
inspection. (See 03-14-2 DIFFERENTIAL OIL INSPECTION.)
12. Install a new washer and the oil filler plug, and tighten.
Tightening torque
39.2— 53.9 N·m {4.0— 5.4 kgf·m, 29.0— 39.7 ft·lbf}
End Of Sie
OIL SEAL (COMPANION FLANGE) REPLACEMENT
id031400800800
1. Drain the differential oil into a container.
2. Remove the propeller shaft. (See 03-15-3 PROPELLER SHAFT REMOVAL/INSTALLATION.)
3. Remove the locknut using the SST.
4. Support the differential using a jack.
49 S120 710
acxuuw00001373
DIFFERENTIAL
JACK
acxuuw00001374
03-14–3
1871-1U-06B(03-14).fm 4 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
6. Pull the companion flange off using the SST.
7. Remove the oil seal from the differential carrier 49 0839 425C
using a screwdriver or similar tool.
8. Apply differential oil to the new oil seal lip.
acxuuw00001375
Tightening torque
167— 226 N·m {17.1— 23.0 kgf·m, 124— 166
ft·lbf}
03-14–4
1871-1U-06B(03-14).fm 5 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
REAR DIFFERENTIAL REMOVAL/INSTALLATION
id031400800400
1. Drain the rear differential oil into a container.
2. Remove the main silencer and middle pipe. (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3
WITH TC].)
3. Remove the propeller shaft. (See 03-15-3 PROPELLER SHAFT REMOVAL/INSTALLATION.)
4. Remove the rear drive shaft. (See 03-13-20 REAR DRIVE SHAFT REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Add the specified rear differential oil. (See 03-14-2 DIFFERENTIAL OIL REPLACEMENT.)
8. Inspect the rear wheel alignment and adjust it if necessary. (See 02-11-4 REAR WHEEL ALIGNMENT.)
75.5—102
{7.70—10.4, 03-14
55.7—75.2}
A B
75.5—102
C {7.70—10.4, 1
D 55.7—75.2}
75.5—102
{7.70—10.4, E
55.7—75.2} 43.1—60.8
F {4.40—6.194,
A 3 31.8—44.8}
B
C 75.5—102
{7.70—10.4,
55.7—75.2}
D
E
22.6—26.4 7
{2.31—2.69,
2 75.5—102 16.7—19.4}
F {7.70—10.4,
55.7—75.2}
75.5—102
{7.70—10.4,
4 55.7—75.2}
6 5
N·m {kgf·m, ft·lbf}
acxuuw00001971
1 Rear crossmember and rear differential component 5 Front differential mounting rubber (LH)
(See 02-14-20 REAR CROSSMEMBER REMOVAL/ 6 Coupling component
INSTALLATION[AWD]) (See 03-19-4 COUPLING COMPONENT
2 Rear differential component REMOVAL/INSTALLATION)
3 Rear differential mounting rubber 7 Rear differential
4 Front differential mounting rubber (RH)
End Of Sie
03-14–5
1871-1U-06B(03-14).fm 6 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
REAR DIFFERENTIAL DISASSEMBLY
id031400800500
Warning
• The engine stand is equipped with a self-lock mechanism, however, if the rear differential is in a
tilted condition, the self-lock mechanism could become inoperative. If the rear differential
unexpectedly rotates it could cause injury, therefore do not maintain the rear differential in a tilted
condition. When turning the rear differential, grasp the rotation handle firmly.
7 3 2
10 6
SST
13 14
11
19
15
5 18 3
23
SST
17
22
21 25 23
21 SST 5
20
1 24 6
22 4
SST
24
16
15
12
8 9
SST
acxuuw00001405
03-14–6
1871-1U-06B(03-14).fm 7 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
23 Side bearing inner race 24 Oil seal
(See 03-14-9 Side Bearing Inner Race Disassembly 25 Gear case
Note)
49 0107 680A
acxuuw00001406
49 0107 680A
49 L027 0A2
acxuuw00001407
acxuuw00001408
49 L027 004
acxuuw00001409
03-14–7
1871-1U-06B(03-14).fm 8 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
Locknut Disassembly Note
1. Remove the locknut using the SSTs.
49 L027 006
49 L027 007
acxuuw00001410
acxuuw00001411
49 H027 002
acxuuw00001412
acxuuw00001413
03-14–8
1871-1U-06B(03-14).fm 9 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
Ring Gear Disassembly Note
1. Secure the gear case in a vice and remove the
bolts.
2. Lightly tap around the ring gear using a plastic
hammer to remove the ring gear from the gear
case.
acxuuw00001414 03-14
Note
• Mark or otherwise distinguish between the left and right side bearings so that they are not mixed up at the
time of reassembly.
49 0839 425C
acxuuw00001415
03-14–9
1871-1U-06B(03-14).fm 10 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
REAR DIFFERENTIAL ASSEMBLY
id031400800600
Warning
• The engine stand is equipped with a self-lock mechanism, however, if the rear differential is in a
tilted condition, the self-lock mechanism could become inoperative. If the rear differential
unexpectedly rotates it could cause injury, therefore do not maintain the rear differential in a tilted
condition. When turning the rear differential, grasp the rotation handle firmly.
Note
• Clean away the old sealant before applying the new sealant.
• Install the rear cover within 10 minutes after applying sealant.
• Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified
oil.
38—51
SEALANT 15.7—22.6
{3.9—6.2, 24 {1.6—2.3,
28.1—37.6} 11.6—16.6}
23
R
SST 38—51
SST 15 {3.9—6.2,
12 11 SEALANT 28.1—37.6}
R 14 8 68.6—83.3
19 {9.0—8.49,
R SST 10 22 50.6—61.4}
6
20 7 23
2
SST
12.7—17.3 R
{1.3—1.7,
2 SST
9.4—12.7}
SST
26 20
25 OIL
3
1
4 4
5
R
3 18
9 26 21
SST
10 SST R OIL
13 R
17
16
R SST
240—755
{24.5—76.9, 177—556}
N·m {kgf·m, ft·lbf}
acxuuw00002352
03-14–10
1871-1U-06B(03-14).fm 11 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
13 Bearing inner race (front bearing) 19 Spacer
(See 03-14-13 Spacer, Bearing Inner Race 20 Side bearing outer race
Assembly Note)
21 Rear differential component
14 Collapsible spacer
22 Adjusting shim (R)
15 Drive pinion
23 Bearing cap
16 Locknut (See 03-14-17 Bearing Cap Assembly Note)
(See 03-14-15 Locknut Assembly Note)
24 Rear cover
17 Washer (See 03-14-18 Rear Cover Assembly Note)
18 Adjusting shim (L) 25 Differential oil temperature sensor
(See 03-14-15 Adjusting Shim Assembly Note)
26 Oil seal
(See 03-14-18 Oil Seal Assembly Note)
03-14
Side Bearing Inner Race Assembly Note
Caution
• Do not mix up the left and right side bearing inner races.
acxuuw00001417
Standard backlash
0.1 mm {0.004 in} or less
acxuuw00001418
03-14–11
1871-1U-06B(03-14).fm 12 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
Ring Gear Assembly Note
Caution
• The differential gear and ring gear could be damaged if the ring gear is installed with old thread-
locking compound remaining on the bolt threads. Before installing the ring gear, completely
remove the old thread-locking compound from the bolt threads.
Tightening torque
68.6— 83.3 N·m {7.00— 8.49 kgf·m, 50.6—
61.4 ft·lbf}
acxuuw00001420
03-14–12
1871-1U-06B(03-14).fm 13 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
Spacer, Bearing Inner Race Assembly Note
Pinion height adjustment
Note
• Use the same spacer.
• Install the spacer with the chamfer on the SST side.
49 G027 005
49 G032 347
acxuuw00001422
49 0727 570
acxuuw00001423
acxuuw00001424
03-14–13
1871-1U-06B(03-14).fm 14 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
9. Add the two (left and right) values obtained by the
measurements taken in Step 8 and then divide
the total by 2. From this result, subtract the result
obtained by dividing the number inscribed on the
end surface of the drive pinion by 100. (If there is
no figure inscribed, use 0.) This is the pinion
height adjustment value.
Note
• For example, the measured results obtained
at Step 8 and 9 are 0.06 mm {0.003 in} and
0.04 mm {0.002 in}, and the figure inscribed
on the end of the drive pinion is 2:
((0.06 mm {0.003 in}+ 0.04 mm {0.002 in}) /
2) – (2/100) = 0.03 mm {0.001 in} (pinion
height adjustment value)
Replace with a spacer 0.03 mm {0.001 in}
thicker than the currently used one. Spacer
thickness is set at 0.015 mm {0.0006 in}
increments, therefore select the closest
spacer thickness and assemble. acxuuw00001425
• Install the spacer with the chamfer on the
SST side.
Spacer thickness
Identification mark Thickness (mm {in}) Identification mark Thickness (mm {in})
08 3.08 {0.1213} 29 3.29 {0.1295}
09 3.095 {0.1219} 30 3.305 {0.1301}
11 3.11 {0.1224} 32 3.32 {0.1307}
12 3.125 {0.1230} 33 3.335 {0.1313}
14 3.14 {0.1236} 35 3.35 {0.1319}
15 3.155 {0.1242} 36 3.365 {0.1325}
17 3.17 {0.1248} 38 3.38 {0.1331}
18 3.185 {0.1254} 39 3.395 {0.1337}
20 3.20 {0.1260} 41 3.41 {0.1343}
21 3.215 {0.1266} 42 3.425 {0.1348}
23 3.23 {0.1272} 44 3.44 {0.1354}
24 3.245 {0.1278} 45 3.455 {0.1360}
26 3.26 {0.1283} 47 3.47 {0.1366}
27 3.275 {0.1289} — —
10. Assemble the spacer selected for the pinion height adjustment to the drive pinion.
11. Press the bearing inner race (rear bearing) into
the drive pinion using the SSTs and a press.
Substitution SST 49 F401 331
• 49 V001 525
Outer diameter: 37.2— 50.3 mm {1.47— 1.98
in}
Inner diameter: 35.2 mm {1.39 in} or more 49 V001 525
Inner depth: 134.3 mm {5.29 in} or more
Plate thickness: 1 mm {0.04 in} or more
acxuuw00001426
03-14–14
1871-1U-06B(03-14).fm 15 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
Locknut Assembly Note
Drive pinion preload adjustment
1. Apply differential oil to a new locknut.
2. Assemble a new collapsible spacer, bearing inner race (front bearing), spacer and locknut to the drive pinion,
and temporarily tighten the locknut.
3. Turn the serrated part of the drive pinion by hand to seat the bearing.
4. Tighten the locknut temporarily tightened in Step
1 from the lower limit of the specified tightening
torque using the SSTs, and make this the 49 L027 006
specified preload.
• If the specified preload cannot be obtained
within the specified tightening torque, replace
the collapsible spacer and inspect again.
03-14
49 L027 007
Tightening torque
167— 226 N·m {17.1— 23.0 kgf·m, 124— 166
ft·lbf}
acxuuw00001427
Rear differential drive pinion preload
1.3— 1.8 N·m {13.3— 18.2 kgf·cm, 11.5— 15.9
in·lbf}
LOCKNUT
acxuuw00001428
acxuuw00001429
03-14–15
1871-1U-06B(03-14).fm 16 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
7. If the combined thickness of the previously installed adjusting shims is not between C1 and C2, or if the
adjusting shims have to be replaced, select two appropriate adjusting shims from the table below.
Adjusting shim thickness
Identification mark Thickness (mm {in}) Identification mark Thickness (mm {in})
350 3.50 {0.137} 410 4.10 {0.161}
355 3.55 {0.139} 415 4.15 {0.163}
360 3.60 {0.141} 420 4.20 {0.165}
365 3.65 {0.143} 425 4.25 {0.167}
370 3.70 {0.145} 430 4.30 {0.169}
375 3.75 {0.147} 435 4.35 {0.171}
380 3.80 {0.149} 440 4.40 {0.173}
385 3.85 {0.151} 445 4.45 {0.175}
390 3.90 {0.153} 450 4.50 {0.177}
395 3.95 {0.155} 455 4.55 {0.179}
400 4.00 {0.157} 460 4.60 {0.181}
405 4.05 {0.159} — —
Caution
• If adjusting shims are to be reused, do not mix up the left and right shims.
• Do not mix up the left and right side bearing outer races and spacers.
8. Assemble the selected adjusting shims to the differential carrier ring gear side, and the spacer to the opposite
side.
9. Assemble the differential and bearing outer race to the differential carrier.
10. Tap the selected adjusting shim between the
spacer and the bearing race with a plastic
hammer as shown in the figure.
11. Align the bearing cap alignment marks to
assemble the bearing cap, and temporarily
tighten the bolts.
12. Place the dial indicator so that the measuring
probe contacts the top surface of one of the ring
gear teeth perpendicularly.
13. Secure the drive pinion and measure the
backlash from when the ring gear moved.
acxuuw00001431
Rear differential backlash of drive pinion and
ring gear
Standard: 0.09— 0.11 mm {0.003— 0.004 in}
Minimum value: 0.05 mm {0.002 in}
Note
• Measure the backlash at 4 locations around the ring gear. Make sure one of the 4 locations is within
specification, and the minimum value for the 4 locations is 0.5 mm {0.002 in} or less.
14. If the backlash is not within the specification, adjust the gear case component by moving it in the axial direction.
Note
• When moving the gear case component in the axial direction, replace the adjusting shims. If the adjusting
shim on the right side is replaced with one that is 0.05 mm {0.002 in} thicker, replace the one on the left
with one that is 0.05 mm {0.002 in} thinner.
03-14–16
1871-1U-06B(03-14).fm 17 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
Bearing Cap Assembly Note
1. Align the bearing cap alignment marks to assemble the bearing cap.
Tightening torque
38— 51 N·m {3.9— 5.2 kgf·m, 28.1— 37.0 ft·lbf}
03-14
acxuuw00001432
acxuuw00001434
acxuuw00001435
03-14–17
1871-1U-06B(03-14).fm 18 ページ 2006年3月15日 水曜日 午前11時7分
DIFFERENTIAL
Rear Cover Assembly Note
Caution
• Clean away the old sealant before applying the new sealant.
• Install the rear differential within 10 minutes after applying sealant.
• Allow the sealant to set at least 30 minutes after installation before filling the differential with the
specified oil.
1. Clean the alignment surface of the carrier and rear cover, and apply a thin coat of sealant.
2. Install the rear cover.
Tightening torque
15.7— 22.6 N·m {1.6— 2.3 kgf·m, 11.6— 16.6 ft·lbf}
acxuuw00001436
03-14–18
1871-1U-06B(03-15).fm 1 ページ 2006年3月15日 水曜日 午前11時8分
PROPELLER SHAFT
03-15 PROPELLER SHAFT
PROPELLER SHAFT PROPELLER SHAFT
LOCATION INDEX. . . . . . . . . . . . . . . . . 03-15–1 REMOVAL/INSTALLATION . . . . . . . . . . 03-15–3
PROPELLER SHAFT Bolt and Nut Removal Note. . . . . . . . . . 03-15–4
ON-VEHICLE INSPECTION . . . . . . . . . 03-15–2 Propeller Shaft Installation Note . . . . . . 03-15–4
Joint Area Excessive Play Inspection . 03-15–2 PROPELLER SHAFT INSPECTION . . . . 03-15–5
Propeller Shaft Runout Inspection . . . . 03-15–2
End of Toc
PROPELLER SHAFT LOCATION INDEX
WM: PROPELLER SHAFT
id031500800100
03-15
acxuuw00000567
1 Propeller shaft
(See03-15-2 PROPELLER SHAFT ON-VEHICLE
INSPECTION.)
(See03-15-3 PROPELLER SHAFT REMOVAL/
INSTALLATION.)
(See03-15-5 PROPELLER SHAFT INSPECTION.)
End Of Sie
03-15–1
1871-1U-06B(03-15).fm 2 ページ 2006年3月15日 水曜日 午前11時8分
PROPELLER SHAFT
PROPELLER SHAFT ON-VEHICLE INSPECTION
id031500800200
Joint Area Excessive Play Inspection
1. Shake the universal joint by hand and verify that
there is no excessive play.
2. If there is any excessive play, replace the
propeller shaft. (See 03-15-3 PROPELLER
SHAFT REMOVAL/INSTALLATION.)
ampjjw00003160
Caution
• Do not rotate the propeller shaft using engine force when inspecting.
End Of Sie
acxuuw00000569
03-15–2
1871-1U-06B(03-15).fm 3 ページ 2006年3月15日 水曜日 午前11時8分
PROPELLER SHAFT
PROPELLER SHAFT REMOVAL/INSTALLATION
id031500800300
1. Remove the negative battery cable.
2. Remove the middle pipe, and front pipe. (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3
WITH TC].)
3. Remove in the order indicated in the figure.
4. Install in the reverse order of removal.
03-15
7
2 9
5
4 1
37.3—52.0
{3.9—5.3, 3
28—38}
acxuuw00000570
03-15–3
1871-1U-06B(03-15).fm 4 ページ 2006年3月15日 水曜日 午前11時8分
PROPELLER SHAFT
Bolt and Nut Removal Note
Caution
• Do not mark with a punch to prevent imbalance.
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acxuuw00000572
03-15–4
1871-1U-06B(03-15).fm 5 ページ 2006年3月15日 水曜日 午前11時8分
PROPELLER SHAFT
PROPELLER SHAFT INSPECTION
id031500800500
1. Measure the propeller shaft center runout using
the dial gauge.
• If it exceeds the maximum specification,
replace the propeller shaft as a single
component.
03-15
acxuuw00000573
End Of Sie
ampjjw00002749
03-15–5
1871-1U-06B(03-16).fm 1 ページ 2006年3月15日 水曜日 午前11時9分
TRANSFER
03-16 TRANSFER
TRANSFER LOCATION INDEX . . . . . . . 03-16–1 TRANSFER OIL COOLER
TRANSFER OIL INSPECTION . . . . . . . . 03-16–2 REMOVAL/INSTALLATION . . . . . . . . . . 03-16–3
TRANSFER OIL REPLACEMENT . . . . . 03-16–2 TRANSFER
TRANSFER OIL SEAL REMOVAL/INSTALLATION . . . . . . . . . . 03-16–3
REPLACEMENT . . . . . . . . . . . . . . . . . . 03-16–2 No.1 Engine Mount Installation Note. . . 03-16–5
End of Toc
TRANSFER LOCATION INDEX
WM: TRANSFER
id031600800100
03-16
1 4
acxuuw00002322
End Of Sie
03-16–1
1871-1U-06B(03-16).fm 2 ページ 2006年3月15日 水曜日 午前11時9分
TRANSFER
TRANSFER OIL INSPECTION
id031600800200
1. Park the vehicle on level ground.
2. Remove the oil level plug and with the washer.
3. Verify that the oil is near the brim of the plug port.
• If the oil level is low, add the specified amount
and type of oil through the oil level plug hole.
Transfer oil
Specified oil grade: API Service GL-5
Specified oil viscosity: SAE 80W-90
Tightening torque
E6U316ZWC002
39.2— 58.8 N·m {4.0— 5.9 kgf·m, 29.0— 43.3
ft·lbf}
End Of Sie
TRANSFER OIL REPLACEMENT
id031600800300
1. Remove the drain plug with the washer.
2. Drain the oil into a suitable container.
3. Tighten the drain plug with a new washer.
Tightening torque
39.2— 58.8 N·m {4.0— 5.9 kgf·m, 29.0— 43.3
ft·lbf}
DRAIN PLUG
4. Remove the oil level plug with the washer and add
the specified amount and type of oil through the
oil level plug hole until the level reaches the
bottom of the oil level plug hole.
E6U316ZWC003
Transfer oil
Specified oil grade: API Service GL-5
Specified oil viscosity: SAE 80W-90
Capacity (approximate quantity): 1.2 L {1.3 US qt, 1.1 lmp qt}
Tightening torque
39.2— 58.8 N·m {4.0— 5.9 kgf·m, 29.0— 43.3 ft·lbf}
End Of Sie
TRANSFER OIL SEAL REPLACEMENT
id031600800400
1. On level ground, jack up the vehicle and support it evenly on safety stands.
2. Drain the oil from the transfer. (See 03-16-2 TRANSFER OIL REPLACEMENT.)
3. Remove the joint shaft. (See 03-13-4 JOINT SHAFT REMOVAL/INSTALLATION[AWD])
4. Remove the oil seals using a screwdriver.
5. Using the SST and a hammer, tap each new oil
-0.8—0.8 mm{-0.03—0.03 in}
seal.
Substitution SST
• 49 T034 201A
Outer diameter: 59— 64 mm {2.33— 2.51 in}
Inner diameter: 55 mm {2.17 in} or more
Plate thickness: 2 mm {0.08 in} or more
Length: 5 mm {0.20 in} or more
6. Coat the lip of each oil seal with transfer oil. OIL SEAL
7. Install the joint shaft. (See 03-13-4 JOINT SHAFT
REMOVAL/INSTALLATION[AWD]) 49 T034 201A
8. Add the specified amount and type of oil. (See 03-
acxuuw00002271
16-2 TRANSFER OIL REPLACEMENT.)
End Of Sie
03-16–2
1871-1U-06B(03-16).fm 3 ページ 2006年3月15日 水曜日 午前11時9分
TRANSFER
TRANSFER OIL COOLER REMOVAL/INSTALLATION
id031600800500
1. Disconnect the propeller shaft from the transfer side. (See 03-15-3 PROPELLER SHAFT REMOVAL/
INSTALLATION.)
2. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT[L3 WITH TC].)
3. Drain the transfer oil into a suitable container. (See 03-16-2 TRANSFER OIL REPLACEMENT.)
4. Remove in the order indicated in the figure.
5. Install in the reverse order of removal.
6. Perform the following procedure, if the transfer has been overhauled and installed to the vehicle.
(1) After warming up the engine, drive the vehicle and inspect for oil leakage and abnormal noise.
23.5—29.4 N·m
2 {2.4—2.9 kgf·m, 17.4—21.6 ft·lbf}
1 03-16
GREASE
R
3
1
GREASE
E6U316ZWC007
End Of Sie
TRANSFER REMOVAL/INSTALLATION
id031600800600
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Battery, battery try (See 01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].)
(2) Engine cover
(3) Intercooler (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
(4) Front pipe (See 01-15-2 EXHAUST SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
3. Disconnect the propeller shaft from the transfer side. (See 03-15-3 PROPELLER SHAFT REMOVAL/
INSTALLATION.)
4. Remove the transfer oil cooler withe the hose still connected. (See 03-16-3 TRANSFER OIL COOLER
REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Warm up the engine and transaxle, inspect for oil leakage, and inspect the transfer operation.
03-16–3
1871-1U-06B(03-16).fm 4 ページ 2006年3月15日 水曜日 午前11時9分
TRANSFER
13
8
C
12
D
14
D 7.8—10.8 N·m
42—62 {80—110 kgf·cm,
{4.3—6.3, 70—95 in·lbf}
31—45}
10
15
9 64—89 16 11
{6.6—9.0,
48—65}
19—27 C
{2.0—2.7,
15—19}
47.0—59.0 93.1—116.6
{4.80—6.01, {9.50—11.88,
34.7—43.5} 68.7—85.9}
42.3—60.1
{4.32—6.12,
85.3—116.6
5
3 31.2—44.3}
{8.70—11.88,
2 62.9—85.9}
43.1—58.8
{4.40—5.99,
4 1 18.6—26.5
A
31.8—43.3} {1.9—2.7,
B
14—19}
6
42.3—60.1 93.1—131.3
{4.32—6.12, {9.5—13.3, 68.7—96.8}
A 31.2—44.3}
119.6—154.8 6
{12.2—15.7, 88.3—114.1}
119.6—154.8 B
{12.2—15.7,
88.3—114.1} 47.0—59.0
2 {4.80—6.01,
119.6—154.8 3 34.7—43.5} 119.6—154.8
{12.2—15.7,
{12.2—15.7,
88.3—114.1}
7 4 88.3—114.1}
43.1—58.8
{4.40—5.99,
31.8—43.3} 93.1—131.3
119.6—154.8
{9.5—13.3,
119.6—154.8 {12.2—15.7,
68.7—96.8}
{12.2—15.7, 88.3—114.1}
88.3—114.1}
03-16–4
1871-1U-06B(03-16).fm 5 ページ 2006年3月15日 水曜日 午前11時9分
TRANSFER
9 Drive shaft 13 WU-TWC
(See 03-13-12 FRONT DRIVE SHAFT REMOVAL/ (See 01-15-2 EXHAUST SYSTEM REMOVAL/
INSTALLATION.) INSTALLATION[L3 WITH TC].)
10 Transfer bracket 14 Heat shield
11 HO2S (front) 15 Joint shaft
(See 01-15-2 EXHAUST SYSTEM REMOVAL/ (See 03-13-4 JOINT SHAFT REMOVAL/
INSTALLATION[L3 WITH TC].) INSTALLATION[AWD].)
12 WU-TWC bracket 16 Transfer
Tightening torque
Bolt A, B: 93.1— 116.6 N·m
{9.50— 11.88 kgf·m, 68.7— 85.9 ft·lbf}
Bolt C: 85.3— 116.6 N·m BOLT C
{87.0— 11.88 kgf·m, 62.9— 85.9 ft·lbf}
acxuuw00000476
03-16–5
1871-1U-06B(03-19).fm 1 ページ 2006年3月15日 水曜日 午前11時9分
End of Toc
ELECTRONIC AWD CONTROL SYSTEM LOCATION INDEX
WM: ELECTRONIC 4WD CONTROL SYSTEM
id031900800100
2 4
acxuuw00001437
End Of Sie
WM: 4WD CONTROL MODULE
03-19–1
1871-1U-06B(03-19).fm 2 ページ 2006年3月15日 水曜日 午前11時9分
Note
• AWD CM terminal voltage can vary depending on measuring conditions and vehicle aging, resulting in
misdiagnosis. Therefore, it is necessary to perform an overall inspection of the input/output systems and
AWD CM to determine which part is malfunctioning.
• With the AWD CM connector connected, measure voltage by connecting the voltmeter negative (-) lead to
the body ground and positive (+) lead to each AWD CM terminal.
1. Measure voltage or resistance at each AWD CM terminal using a voltmeter and an ohmmeter.
• If not as specified, replace the AWD CM.
O M K I G E C A
P N L J H F D B
acxuuw00001438
03-19–2
1871-1U-06B(03-19).fm 3 ページ 2006年3月15日 水曜日 午前11時9分
End Of Sie
AWD CONTROL MODULE REMOVAL/INSTALLATION
id031900800300
1. Disconnect the negative battery cable.
2. Remove the lower panel (Driver’s side). (See 09-17-9 LOWER PANEL REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
03-19
2 3
1
8.8—12.7
{90—129 , 78—112}
acxuuw00001972
1 Bolt 3 Connector
2 AWD CM
(See 03-19-3 AWD CM Removal Note.)
AWD CM
acxuuw00001973
03-19–3
1871-1U-06B(03-19).fm 4 ページ 2006年3月15日 水曜日 午前11時9分
75.5—102 22.6—26.4
{7.70—10.4, {2.31—2.69,
55.7—75.2} 16.7—19.4}
2
SEALANT
3 75.5—102
{7.70—10.4,
55.7—75.2}
N·m {kgf·m, ft·lbf}
acxuuw00001974
OIL PAN
SEAL CUTTER
acxuuw00001441
03-19–4
1871-1U-06B(03-19).fm 5 ページ 2006年3月15日 水曜日 午前11時9分
Note
• Clean away the old sealant before applying the new sealant.
• Install the coupling unit within 10 min after applying sealant.
• Allow the sealant to set at least 30 min after installation before filling the differential with the specified oil.
1. Apply sealant to the coupling case surface that contacts the rear differential case.
2. Install the coupling unit to the rear differential so
that the two tabs on the coupling unit engage the
rear differential grooves (two locations).
Tightening torque
03-19
22.6— 26.4 N·m {2.4— 2.6 kgf·m, 16.7— 19.4
ft·lbf}
Warning
• The engine stand is equipped with a self-lock mechanism, however, if the coupling unit is in a
tilted condition, the self-lock mechanism could become inoperative. If the coupling unit
unexpectedly rotates it could cause injury, therefore do not maintain the coupling unit in a tilted
condition. When turning the coupling unit, grasp the rotation handle firmly.
10
SST
9
7 5
6
SST 4
3 SST
2
SST
1
acxuuw00001443
03-19–5
1871-1U-06B(03-19).fm 6 ページ 2006年3月15日 水曜日 午前11時9分
49 L027 0A2
49 0107 680A
acxuuw00001444
49 L027 0A2
acxuuw00002359
49 S120 710
acxuuw00001446
49 0839 425C
acxuuw00002356
03-19–6
1871-1U-06B(03-19).fm 7 ページ 2006年3月15日 水曜日 午前11時9分
03-19
acxuuw00001448
acxuuw00001449
49 S033 108
acxuuw00001450
03-19–7
1871-1U-06B(03-19).fm 8 ページ 2006年3月15日 水曜日 午前11時9分
Warning
• The engine stand is equipped with a self-lock mechanism, however, if the coupling unit is in a
tilted condition, the self-lock mechanism could become inoperative. If the coupling unit
unexpectedly rotates it could cause injury, therefore do not maintain the coupling unit in a tilted
condition. When turning the coupling unit, grasp the rotation handle firmly.
41.2—53.9
5 {4.2—5.4, 30.4—39.7}
SST 1
3 SST
4 2
6 SST
OIL
R
SST 7
SST R
167—226
{17.1—23.0,
124—166}
10
9 8
N·m {kgf·m, ft·lbf}
acxuuw00001451
03-19–8
1871-1U-06B(03-19).fm 9 ページ 2006年3月15日 水曜日 午前11時9分
03-19
acxuuw00001452
acxuuw00001453
Caution
• The coupling unit will be damaged if it is pressed directly by a press. Always press the coupling
unit into the coupling case using the SST.
acxuuw00001454
acxuuw00001455
03-19–9
1871-1U-06B(03-19).fm 10 ページ 2006年3月15日 水曜日 午前11時9分
49 L027 0A2
acxuuw00002358
End Of Sie
WM: DIFFERENTIAL OIL TEMPERATURE SENSOR
acxuuw00001457
DIFFERENTIAL OIL TEMPERATURE SENSOR INSPECTION
id031900800700
Warning
• Hot differential oil may cause severe burns. Do not perform maintenance while differential oil is
hot.
acxuuw00001458
4. Install the differential oil temperature sensor and connect the connector.
5. Connect the negative battery cable.
03-19–10
1871-1U-06B(03-19).fm 11 ページ 2006年3月15日 水曜日 午前11時9分
Warning
• Hot differential oil may cause severe burns. Do not perform maintenance while differential oil is
hot.
03-19–11
1871-1U-06B(03-50).fm 1 ページ 2006年3月15日 水曜日 午前11時10分
TECHNICAL DATA
03-50 TECHNICAL DATA
DRIVELINE/AXLE TECHNICAL DATA . . 03-50–1
End of Toc
DRIVELINE/AXLE TECHNICAL DATA
WM: DRIVELINE/AXLE
id035000800100
Item Specification
Front wheel bearing maximum play 0.05 mm {0.002 in}
Rear wheel bearing maximum play 0.05 mm {0.002 in}
LH: 658.2—668.2 mm {25.92—26.30 in}
Front drive shaft length
RH: 621.2—631.2 mm {24.46—24.85 in} 03-50
LH: 840.8—850.8 mm {33.11—33.49 in}
Rear drive shaft length
RH: 862.3—872.3 mm {33.95—34.34 in}
Specified oil grade: API service GL-5
Rear differential oil Specified oil viscosity: SAE 80W-90
Capacity (approximate quantity): 1.00 L {1.06 US qt, 0.88 Imp qt}
Rear differential backlash of pinion gear and side gear 0.1 mm {0.004 in} or less
Rear differential pinion height –0.032—0.032 mm {–0.0012—0.0012 in}
Rear differential drive pinion preload 1.3—1.8 N·m {13.3—18.2 kgf·cm, 11.5—15.9 in·lbf}
Standard: 0.09—0.11 mm {0.003—0.004 in}
Rear differential backlash of drive pinion and ring gear
Minimum value: 0.05 mm {0.002 in}
Propeller shaft maximum runout 0.8 mm {0.031 in}
Propeller shaft starting torque 0.29—1.47 N·m {3.0—14.9 kgf·cm, 2.6—13.0 in·lbf}
Specified oil grade: API Service GL-5
Transfer oil Specified oil viscosity: SAE 80W-90
Capacity (approximate quantity): 1.2 L {1.3 US qt, 1.1 lmp qt}
End Of Sie
03-50–1
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
SERVICE TOOLS
03-60 SERVICE TOOLS
DRIVELINE/AXLE SST . . . . . . . . . . . . . . 03-60–1
End of Toc
DRIVELINE/AXLE SST
WM: DRIVELINE/AXLE
id036000800200
03-60
03-60–1
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
SERVICE TOOLS
49 L027 006 49 L027 007 49 F401 331
End Of Sie
BRAKES 04SECTION
Toc of SCT
ON-BOARD DIAGNOSTIC . . . . 04-02 PARKING BRAKE
SYMPTOM SYSTEM. . . . . . . . . . . . . . . . . 04-12
TROUBLESHOOTING . . . . . . 04-03 DYNAMIC STABILITY
GENERAL PROCEDURES . . . . 04-10 CONTROL . . . . . . . . . . . . . . . 04-15
CONVENTIONAL TECHNICAL DATA . . . . . . . . . . 04-50
BRAKE SYSTEM . . . . . . . . . . 04-11 SERVICE TOOLS . . . . . . . . . . . 04-60 04-02
Toc of SCT
04-02 ON-BOARD DIAGNOSTIC
SYSTEM WIRING DIAGRAM . . . . . . . . . . 04-02–2 DTC C1141, C1142, C1143, C1144. . . . . 04-02–14
ON-BOARD DIAGNOSIS . . . . . . . . . . . . . 04-02–3 DTC C1145, C1155, C1165, C1175. . . . . 04-02–15
On-Board Diagnostic (OBD) Test DTC C1148, C1158, C1168, C1178. . . . . 04-02–17
Description . . . . . . . . . . . . . . . . . . . . . 04-02–3 DTC C1186, C1266 . . . . . . . . . . . . . . . . . 04-02–19
Reading DTCs Procedure . . . . . . . . . . . 04-02–3 DTC C1194, C1198, C1210, C1214,
Clearing DTCs Procedures . . . . . . . . . . 04-02–3 C1242, C1246, C1250, C1254, C1400,
PID/Data Monitor and Record C1410, C1957, C1958. . . . . . . . . . . . . . 04-02–20
Procedure . . . . . . . . . . . . . . . . . . . . . . 04-02–4 DTC C1222 . . . . . . . . . . . . . . . . . . . . . . . 04-02–20
Active Command Modes Procedure . . . 04-02–4 DTC C1233, C1234, C1235, C1236. . . . . 04-02–22
DTC Table . . . . . . . . . . . . . . . . . . . . . . . 04-02–5 DTC C1279, C1280, C1281, C1282,
PID/DATA Monitor Table . . . . . . . . . . . . 04-02–6 C1951, C1952, C1959, C2768 . . . . . . . . 04-02–24
Active Command Modes Table . . . . . . . 04-02–9 DTC C1288, C1290, C1953 . . . . . . . . . . . 04-02–27
DTC B1317, B1318. . . . . . . . . . . . . . . . . . 04-02–9 DTC C1295, C1307, C1937, C1938. . . . . 04-02–28
DTC B1342, C1730. . . . . . . . . . . . . . . . . . 04-02–11 DTC C1306 . . . . . . . . . . . . . . . . . . . . . . . 04-02–29
DTC B1484, C1954. . . . . . . . . . . . . . . . . . 04-02–11 DTC C1414 . . . . . . . . . . . . . . . . . . . . . . . 04-02–30
DTC C1095, C1096. . . . . . . . . . . . . . . . . . 04-02–12 DTC C1994 . . . . . . . . . . . . . . . . . . . . . . . 04-02–30
End of Toc
WM: DYNAMIC STABILITY CONTROL
04-02–1
1871-1U-06B(04-02).fm 2 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
SYSTEM WIRING DIAGRAM
id040200804800
ABS 2 20A
C IG 1
E
ABS 1 40A Y F
B AB C COMBINED
AE A SENSOR
AA B
AI D
A
DSC 7.5A
J
IG SW
BATTERY STEERING
BCM ANGLE
SENSOR
BRAKE SYSTEM ABS WARNING
WARNING LIGHT LIGHT
CAN_L
CAN_H
DSC HU/CM
DSC INDICATOR
LIGHT
CAN
DRIVER
CAN_H
INSTRUMENT CLUSTER X CAN
PCM W DRIVER
CAN_L
CAN BRAKE SWITCH
DRIVER N
TCM
CAN
DRIVER
TSC OFF SWITCH
P
DLC-2
CAN_L
CAN_H
RF M
O
LF F
E
ABS WHEEL-
SPEED SENSOR
RR I
L
LR G
H D
acxuuw00002204
End Of Sie
04-02–2
1871-1U-06B(04-02).fm 3 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
ON-BOARD DIAGNOSIS
id040200800200
On-Board Diagnostic (OBD) Test Description
• The OBD test inspects the integrity and function of the DSC and outputs the results when requested by the
specific tests.
• On-board diagnostic test also:
— Provides a quick inspection of the DSC usually performed at the start of each diagnostic procedure.
— Provides verification after repairs to ensure that no other faults occurred during service.
• The OBD test is divided into 3 tests:
— Read/clear diagnostic results, PID monitor and record and active command modes.
04-02–3
1871-1U-06B(04-02).fm 4 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
PID/Data Monitor and Record Procedure
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (notebook PC)
1. Select the “Toolbox” tab.
2. Select “DataLogger”.
3. Select “Module”.
4. Select “ABS”.
• When using the PDS (pocket PC)
1. Select “Module Tests”.
2. Select “ABS”.
DLC-2
3. Select “DataLogger”.
acxuuw00001207
3. Select the applicable PID from the PID table.
4. Verify the PID data according to the directions on
the screen.
Note
• The PID/Data monitor function is used for monitoring the calculated value. Therefore, if the monitored
value of the output parts is not within the specification, inspection of the monitored value of input parts
corresponding to applicable output part control is necessary. In addition, because the system does not
display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output
part individually using a active command modes function.
04-02–4
1871-1U-06B(04-02).fm 5 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
DTC Table
DTC
System malfunction location Page
M-MDS
B1317 Power supply system (See 04-02-9 DTC B1317, B1318.)
B1318 Power supply system (See 04-02-9 DTC B1317, B1318.)
B1342 DSC HU/CM system (See 04-02-11 DTC B1342, C1730.)
B1484 Brake switch system (See 04-02-11 DTC B1484, C1954.)
C1095 Pump motor, motor relay system (See 04-02-12 DTC C1095, C1096.)
C1096 Pump motor, motor relay system (See 04-02-12 DTC C1095, C1096.)
C1141 LF ABS sensor rotor system (See 04-02-14 DTC C1141, C1142, C1143, C1144.)
C1142 RF ABS sensor rotor system (See 04-02-14 DTC C1141, C1142, C1143, C1144.)
C1143 LR ABS sensor rotor system (See 04-02-14 DTC C1141, C1142, C1143, C1144.)
C1144 RR ABS sensor rotor system (See 04-02-14 DTC C1141, C1142, C1143, C1144.)
RF ABS wheel-speed sensor (open circuit) (See 04-02-15 DTC C1145, C1155, C1165, C1175.) 04-02
C1145
system
RF ABS wheel-speed sensor/ABS sensor rotor (See 04-02-17 DTC C1148, C1158, C1168, C1178.)
C1148
system
LF ABS wheel-speed sensor (open circuit) (See 04-02-15 DTC C1145, C1155, C1165, C1175.)
C1155
system
LF ABS wheel-speed sensor/ABS sensor rotor (See 04-02-17 DTC C1148, C1158, C1168, C1178.)
C1158
system
RR ABS wheel-speed sensor (open circuit) (See 04-02-15 DTC C1145, C1155, C1165, C1175.)
C1165
system
RR ABS wheel-speed sensor/ABS sensor rotor (See 04-02-17 DTC C1148, C1158, C1168, C1178.)
C1168
system
LR ABS wheel-speed sensor (open circuit) (See 04-02-15 DTC C1145, C1155, C1165, C1175.)
C1175
system
LR ABS wheel-speed sensor/ABS sensor rotor (See 04-02-17 DTC C1148, C1158, C1168, C1178.)
C1178
system
C1186 Valve relay system (See 04-02-19 DTC C1186, C1266.)
(See 04-02-20 DTC C1194, C1198, C1210, C1214, C1242,
C1194 LF outlet solenoid valve system
C1246, C1250, C1254, C1400, C1410, C1957, C1958.)
(See 04-02-20 DTC C1194, C1198, C1210, C1214, C1242,
C1198 LF inlet solenoid valve system
C1246, C1250, C1254, C1400, C1410, C1957, C1958.)
(See 04-02-20 DTC C1194, C1198, C1210, C1214, C1242,
C1210 RF outlet solenoid valve system
C1246, C1250, C1254, C1400, C1410, C1957, C1958.)
(See 04-02-20 DTC C1194, C1198, C1210, C1214, C1242,
C1214 RF inlet solenoid valve system
C1246, C1250, C1254, C1400, C1410, C1957, C1958.)
C1222 ABS wheel-speed sensor (slip monitor) system (See 04-02-20 DTC C1222.)
LF ABS wheel-speed sensor (short to ground) (See 04-02-22 DTC C1233, C1234, C1235, C1236.)
C1233
system
RF ABS wheel-speed sensor (short to ground) (See 04-02-22 DTC C1233, C1234, C1235, C1236.)
C1234
system
RR ABS wheel-speed sensor (short to ground) (See 04-02-22 DTC C1233, C1234, C1235, C1236.)
C1235
system
LR ABS wheel-speed sensor (short to ground) (See 04-02-22 DTC C1233, C1234, C1235, C1236.)
C1236
system
(See 04-02-20 DTC C1194, C1198, C1210, C1214, C1242,
C1242 LR outlet solenoid valve system
C1246, C1250, C1254, C1400, C1410, C1957, C1958.)
(See 04-02-20 DTC C1194, C1198, C1210, C1214, C1242,
C1246 RR outlet solenoid valve system
C1246, C1250, C1254, C1400, C1410, C1957, C1958.)
(See 04-02-20 DTC C1194, C1198, C1210, C1214, C1242,
C1250 LR inlet solenoid valve system
C1246, C1250, C1254, C1400, C1410, C1957, C1958.)
(See 04-02-20 DTC C1194, C1198, C1210, C1214, C1242,
C1254 RR inlet solenoid valve system
C1246, C1250, C1254, C1400, C1410, C1957, C1958.)
C1266 Valve relay system (See 04-02-19 DTC C1186, C1266.)
(See 04-02-24 DTC C1279, C1280, C1281, C1282, C1951,
C1279 Combined sensor system
C1952, C1959, C2768.)
(See 04-02-24 DTC C1279, C1280, C1281, C1282, C1951,
C1280 Combined sensor system
C1952, C1959, C2768.)
04-02–5
1871-1U-06B(04-02).fm 6 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
DTC
System malfunction location Page
M-MDS
(See 04-02-24 DTC C1279, C1280, C1281, C1282, C1951,
C1281 Combined sensor system
C1952, C1959, C2768.)
(See 04-02-24 DTC C1279, C1280, C1281, C1282, C1951,
C1282 Combined sensor system
C1952, C1959, C2768.)
C1288 Brake fluid pressure sensor system (See 04-02-27 DTC C1288, C1290, C1953.)
C1290 Brake fluid pressure sensor system (See 04-02-27 DTC C1288, C1290, C1953.)
C1295 Steering angle sensor system (See 04-02-28 DTC C1295, C1307, C1937, C1938.)
Steering angle sensor (abnormal initialization) (See 04-02-29 DTC C1306.)
C1306
system
C1307 Steering angle sensor system (See 04-02-28 DTC C1295, C1307, C1937, C1938.)
(See 04-02-20 DTC C1194, C1198, C1210, C1214, C1242,
C1400 RF traction control solenoid valve system
C1246, C1250, C1254, C1400, C1410, C1957, C1958.)
(See 04-02-20 DTC C1194, C1198, C1210, C1214, C1242,
C1410 LF traction control solenoid valve system
C1246, C1250, C1254, C1400, C1410, C1957, C1958.)
C1414 Incorrect DSC HU/CM installed (See04-02-30 DTC C1414.)
C1730 DSC HU/CM system (See 04-02-11 DTC B1342, C1730.)
C1937 Steering angle sensor system (See 04-02-28 DTC C1295, C1307, C1937, C1938.)
C1938 Steering angle sensor system (See 04-02-28 DTC C1295, C1307, C1937, C1938.)
(See 04-02-24 DTC C1279, C1280, C1281, C1282, C1951,
C1951 Combined sensor system
C1952, C1959, C2768.)
(See 04-02-24 DTC C1279, C1280, C1281, C1282, C1951,
C1952 Combined sensor system
C1952, C1959, C2768.)
C1953 Brake fluid pressure sensor system (See 04-02-27 DTC C1288, C1290, C1953.)
C1954 Brake switch system (See 04-02-11 DTC B1484, C1954.)
(See 04-02-20 DTC C1194, C1198, C1210, C1214, C1242,
C1957 RF DSC switch solenoid valve system
C1246, C1250, C1254, C1400, C1410, C1957, C1958.)
(See 04-02-20 DTC C1194, C1198, C1210, C1214, C1242,
C1958 LF DSC switch solenoid valve system
C1246, C1250, C1254, C1400, C1410, C1957, C1958.)
(See 04-02-24 DTC C1279, C1280, C1281, C1282, C1951,
C1959 Combined sensor system
C1952, C1959, C2768.)
C1994 DSC control system (See 04-02-30 DTC C1994.)
(See 04-02-24 DTC C1279, C1280, C1281, C1282, C1951,
C2768 Combined sensor system
C1952, C1959, C2768.)
(See 09-02D-7 DTC TABLE[MULTIPLEX
U0073 CAN system communication error
COMMUNICATION SYSTEM].)
(See 09-02D-7 DTC TABLE[MULTIPLEX
U0100 Communication error to PCM
COMMUNICATION SYSTEM].)
(See 09-02D-7 DTC TABLE[MULTIPLEX
U0101 Communication error to TCM
COMMUNICATION SYSTEM].)
(See 09-02D-7 DTC TABLE[MULTIPLEX
U0114 Communication error to AWD CM
COMMUNICATION SYSTEM].)
(See 09-02D-7 DTC TABLE[MULTIPLEX
U0140 Communication error to BCM
COMMUNICATION SYSTEM].)
(See 09-02D-7 DTC TABLE[MULTIPLEX
U1900 Communication error to other module
COMMUNICATION SYSTEM].)
(See 09-02D-7 DTC TABLE[MULTIPLEX
U2023 Abnormal message from PCM
COMMUNICATION SYSTEM].)
04-02–6
1871-1U-06B(04-02).fm 7 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
PID name Operation condition DSC HU/CM
Unit/Condition Action
(definition) (reference) terminal
BOO_ABS • Brake pedal depressed: Inspect the brake switch.
(Brake pedal switch On/Off On (See 04-11-9 BRAKE SWITCH N
input) • Brake pedal released: Off INSPECTION.)
CCNTABS Perform the DTC inspection.
(Number of continuous — Indicates number of DTC (See 04-02-3 ON-BOARD —
codes) DIAGNOSIS.)
• Vehicle stopped or driving
at constant speed: 0 G
Inspect the combined sensor.
• Cornering to right:
LAT_ACCL G (See 04-15-16 COMBINED AI
Changes 0 G— positive
SENSOR INSPECTION.)
• Cornering to left: Changes
0 G— negative
• Brake pedal released: 0
Inspect the brake fluid pressure
Pa, 0 psi 04-02
sensor.
MCYLI P Pa, psi • Brake pedal depressed: —
(See 04-15-4 DSC SYSTEM
Changes according to the
INSPECTION.)
brake fluid pressure
PMP_MOTOR • Pump motor activated: On Inspect the DSC HU/CM.
(Pump motor output On/Off • Pump motor not activated: (See 04-15-4 DSC SYSTEM —
state) Off INSPECTION.)
RLY_PMP Inspect the DSC HU/CM.
• Relay activated: On
(Motor relay output On/Off (See 04-15-4 DSC SYSTEM —
• Relay not activated: Off
state) INSPECTION.)
RLY_VLV • Valve relay is activated: On Inspect the DSC HU/CM.
(Valve relay output On/Off • Valve relay is deactivated: (See 04-15-4 DSC SYSTEM —
state) Off INSPECTION.)
Inspect the PCM.
RPM • Engine stopped: 0 RPM
(See 01-40-6 PCM
(Engine speed signal RPM • Engine speed at 3,000 —
INSPECTION[L3 WITH TC].)
input) rpm: 3,000 RPM
Inspect the instrument cluster.
• Steering wheel in neutral
position (not turned): 0°
• Steering wheel turned to
Inspect the steering angle sensor.
left: Changes 0°—
SWA_POS ° (See 09-40-7 STEERING ANGLE —
negative
SENSOR INSPECTION.)
• Steering wheel turned to
right: Changes 0°—
positive
• Closed throttle position:
0%
• Wide open throttle: Inspect the throttle position
TPI % —
Changes according to sensor.
throttle valve opening
angle
• Solenoid valve activated:
V_LF_INL Inspect the DSC HU/CM.
On
(Left front inlet solenoid On/Off (See 04-15-4 DSC SYSTEM —
• Solenoid valve not
valve output state) INSPECTION.)
activated: Off
V_LF_OTL • Solenoid valve activated:
Inspect the DSC HU/CM.
(Left front outlet On
On/Off (See 04-15-4 DSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
• Solenoid valve activated:
V_LR_INL Inspect the DSC HU/CM.
On
(Left rear inlet solenoid On/Off (See 04-15-4 DSC SYSTEM —
• Solenoid valve not
valve output state) INSPECTION.)
activated: Off
V_LR_OTL • Solenoid valve activated:
Inspect the DSC HU/CM.
(Left rear outlet On
On/Off (See 04-15-4 DSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_RF_INL • Solenoid valve activated:
Inspect the DSC HU/CM.
(Right front inlet On
On/Off (See 04-15-4 DSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
04-02–7
1871-1U-06B(04-02).fm 8 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
PID name Operation condition DSC HU/CM
Unit/Condition Action
(definition) (reference) terminal
V_RF_OTL • Solenoid valve activated:
Inspect the DSC HU/CM.
(Right front outlet On
On/Off (See 04-15-4 DSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_RR_INL • Solenoid valve activated:
Inspect the DSC HU/CM.
(Right rear inlet On
On/Off (See 04-15-4 DSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_RR_OTL • Solenoid valve activated:
Inspect the DSC HU/CM.
(Right rear outlet On
On/Off (See 04-15-4 DSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_STB_L • Solenoid valve activated:
Inspect the DSC HU/CM.
(LF stability control On
On/Off (See 04-15-4 DSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_STB_R • Solenoid valve activated:
Inspect the DSC HU/CM.
(RF stability control On
On/Off (See 04-15-4 DSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_TRC_L • Solenoid valve activated:
Inspect the DSC HU/CM.
(LF traction control On
On/Off (See 04-15-4 DSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
V_TRC_R • Solenoid valve activated:
Inspect the DSC HU/CM.
(RF traction control On
On/Off (See 04-15-4 DSC SYSTEM —
solenoid valve output • Solenoid valve not
INSPECTION.)
state) activated: Off
Inspect the ABS wheel-speed
• Vehicle stopped: 0 KPH, 0
WSPD_LF sensor.
MPH
(Left front ABS wheel- KPH, MPH (See 04-15-12 FRONT ABS F, E
• Vehicle running: vehicle
speed sensor input) WHEEL-SPEED SENSOR
speed
INSPECTION.)
Inspect the ABS wheel-speed
sensor.
• Vehicle stopped: 0 KPH, 0 (See 04-15-14 REAR ABS
WSPD_LR
MPH WHEEL-SPEED SENSOR
(Left rear ABS wheel- KPH, MPH G, H
• Vehicle running: Vehicle INSPECTION[2WD].)
speed sensor input)
speed (See 04-15-14 REAR ABS
WHEEL-SPEED SENSOR
INSPECTION[AWD].)
Inspect the ABS wheel-speed
• Vehicle stopped: 0 KPH, 0
WSPD_RF sensor.
MPH
(Right front ABS wheel- KPH, MPH (See 04-15-12 FRONT ABS M, O
• Vehicle running: vehicle
speed sensor input) WHEEL-SPEED SENSOR
speed
INSPECTION.)
Inspect the ABS wheel-speed
sensor.
• Vehicle stopped: 0 KPH, 0 (See 04-15-14 REAR ABS
WSPD_RR
MPH WHEEL-SPEED SENSOR
(Right rear ABS wheel- KPH, MPH I, L
• Vehicle running: Vehicle INSPECTION[2WD].)
speed sensor input)
speed (See 04-15-14 REAR ABS
WHEEL-SPEED SENSOR
INSPECTION[AWD].)
• Vehicle stopped or driving
straight: 0 °/s
Inspect the combined sensor.
• Cornering to left: Changes
YAW_RATE °/s (See 04-15-16 COMBINED AA
0 °/s— negative
SENSOR INSPECTION.)
• Cornering to right:
Changes 0 °/s— positive
04-02–8
1871-1U-06B(04-02).fm 9 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
Active Command Modes Table
Operating
Command name Output part Operation
condition
LATACCEL Combined sensor (lateral acceleration) initialization FALSE/TRUE
PMP_MOTOR Pump motor On/Off
SAS_CAL Steering angle sensor initialization FALSE/TRUE
STAB_IND DSC indicator light
TRAC OFF TCS OFF light
V_LF_INL LF inlet solenoid valve
V_LF_OTL LF outlet solenoid valve
V_LR_INL LR inlet solenoid valve
V_LR_OTL LR outlet solenoid valve Ignition switch at
V_RF_INL RF inlet solenoid valve ON
V_RF_OTL RF outlet solenoid valve On/Off 04-02
V_RR_INL RR inlet solenoid valve
V_RR_OTL RR outlet solenoid valve
V_STB_L LF stability control solenoid valve
V_STB_R RF stability control solenoid valve
V_TRC_L LF traction control solenoid valve
V_TRC_R RF traction control solenoid valve
YAWRATE Combined sensor (yaw rate) initialization
End Of Sie
DTC B1317, B1318
id040200800300
IG SW
J
DSC 7.5A
DSC HU/CM
D
BATTERY
AS AQ AO AM AK AI AG AE AC AA Y W U S Q O M K I G E
D C B A
AT AR AP AN AL AJ AH AF AD AB Z X V T R P N L J H F
04-02–9
1871-1U-06B(04-02).fm 10 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT BATTERY VOLTAGE Yes Make sure that battery terminal connection is normal.
• Is the battery terminal voltage normal? Go to the next step.
No Charge or replace the battery, then go to Step 6.
(See 01-17-4 BATTERY RECHARGING[L3 WITH TC].)
(See 01-17-2 BATTERY REMOVAL/INSTALLATION[L3
WITH TC].)
2 INSPECT BATTERY GRAVITY Yes Go to the next step.
• Is battery specific gravity as specified? No Replace the battery, then go to Step 6.
(See 01-17-4 GENERATOR REMOVAL/INSTALLATION[L3
WITH TC].)
3 INSPECT CHARGING SYSTEM Yes Go to the next step.
• Are the generator and drive belt tensions No Replace generator and/or drive belt as necessary, then go
normal? to Step 6.
(See 01-10-3 DRIVE BELT REMOVAL/INSTALLATION[L3
WITH TC].)
(See 01-17-4 GENERATOR REMOVAL/INSTALLATION[L3
WITH TC].)
4 INSPECT ABS HU/CM POWER SUPPLY FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Start the engine. between the DSC HU/CM and ground, then go to Step 6.
• Measure the voltage between DSC HU/CM
terminal J and ground.
• Is the voltage approx. 10 V?
5 INSPECT DSC HU/CM GROUND FOR POOR Yes Go to the next step.
GROUND OR OPEN CIRCUIT No If there is no continuity:
• Turn the ignition switch off. • Repair or replace the wiring harness for open circuit
• Measure the resistance between ground and between the DSC HU/CM and ground, then go to the
DSC HU/CM terminal D. next step.
• Is the resistance within 0— 1 ohm? If the resistance is not within 0— 1 ohm:
• Repair or replace the wiring harness for poor ground,
then go to the next step.
6 VERIFY TROUBLESHOOTING COMPLETED Yes Replace the DSC HU/CM, then go to the next step.
• Make sure to reconnect all disconnected (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
connectors. No Go to the next step.
• Clear the DTC from the memory.
(See 04-02-3 ON-BOARD DIAGNOSIS.)
• Start the engine and drive the vehicle at 10
km/h {6.2 mph} or more.
• Is the same DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
04-02–10
1871-1U-06B(04-02).fm 11 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
DTC B1342, C1730
id040200800400
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY CURRENT STATUS OF Yes Replace the DSC HU/CM, then go to the next step.
MALFUNCTION (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Clear the DTC from the memory. No Go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.) 04-02
• Start the engine and drive the vehicle at 10
km/h {6.2 mph} or more.
• Is the same DTC present?
2 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
DTC B1484, C1954
id040200800500
BRAKE SWITCH
N D B
DSC HU/CM
BRAKE LIGHT
AS AQ AO AM AK AI AG AE AC AA Y W U S Q O M K I G E
D C B A
AT AR AP AN AL AJ AH AF AD AB Z X V T R P N L J H F
C A
D B
04-02–11
1871-1U-06B(04-02).fm 12 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DSC HU/CM TO BRAKE SWITCH Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Turn the ignition switch off. between DSC HU/CM and brake switch, then go to the next
• Disconnect the DSC HU/CM and brake step.
switch connector.
• Inspect for continuity DSC HU/CM terminal N
and brake switch terminal D.
• Is there continuity?
2 INSPECT BRAKE SWITCH Yes Go to the next step.
• Inspect the brake switch. No Replace the brake switch, then go to the next step.
(See 04-11-9 BRAKE SWITCH (See 04-11-6 BRAKE PEDAL REMOVAL/INSTALLATION.)
INSPECTION.)
• Is the brake switch normal?
3 VERIFY TROUBLESHOOTING COMPLETED Yes Replace the DSC HU/CM, then go to the next step.
• Make sure to reconnect all disconnected (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
connectors. No Go to the next step.
• Clear the DTC from the memory.
(See 04-02-3 ON-BOARD DIAGNOSIS.)
• Are the same DTCs present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTC present? (See 04-02-3 ON-BOARD DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
DTC C1095, C1096
id040200800800
DSC HU/CM
B
ABS 1 40A
PUMP
BATTERY MOTOR
A
AS AQ AO AM AK AI AG AE AC AA Y W U S Q O M K I G E
D C B A
AT AR AP AN AL AJ AH AF AD AB Z X V T R P N L J H F
04-02–12
1871-1U-06B(04-02).fm 13 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT ABS FUSE CONDITION Yes Go to the next step.
• Is the ABS 1 40A fuse normal? No Replace the fuse, then go to Step 5.
2 INSPECT MOTOR RELAY POWER SUPPLY Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Turn the ignition switch off. between battery positive terminal and DSC HU/CM terminal
• Disconnect DSC HU/CM connector. B, then go to Step 5.
• Turn the ignition switch to the ON position
(engine off).
• Measure voltage between DSC HU/CM
terminal B (harness-side) and ground.
• Is the voltage B+?
3 INSPECT PUMP MOTOR GROUND FOR Yes Go to the next step.
OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Turn the ignition switch off. between DSC HU/CM terminal A and ground, then go to 04-02
• Inspect for continuity between DSC HU/CM Step 5.
terminal A (harness-side) and ground.
• Is there continuity?
4 VERIFY PUMP MOTOR OPERATION Yes Go to the next step.
• Turn the ignition switch off. No Replace the DSC HU/CM, then go to the next step.
• Connect the M-MDS to the DLC-2. (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Turn the ignition switch to the ON position
(engine off).
• Access PMP_MOTOR active command
modes using the M-MDS.
• Does the pump motor operate?
5 VERIFY TROUBLESHOOTING COMPLETED Yes Replace the DSC HU/CM, then go to the next step.
• Make sure to reconnect all disconnected (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
connectors. No Go to the next step.
• Clear the DTC from the memory.
(See 04-02-3 ON-BOARD DIAGNOSIS.)
• Start the engine and drive the vehicle at 10
km/h {6.2 mph} or more.
• Gradually slow down and stop the vehicle.
• Is the same DTC present?
6 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
04-02–13
1871-1U-06B(04-02).fm 14 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
DTC C1141, C1142, C1143, C1144
id040200801000
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PID FOR ABS WHEEL-SPEED Yes Go to Step 4.
SENSOR OUTPUT ERROR USING M-MDS No Go to the next step.
• Turn the ignition switch off.
• Connect the M-MDS to the DLC-2.
• Select the following PIDs using the M-MDS:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
• Drive the vehicle.
• Verify that the vehicle speeds detected by
the four ABS wheel-speed sensors are
approximately the same.
• Are the vehicle speeds approximately the
same?
2 INSPECT IF MALFUNCTION OCCURRED Yes Go to the next step.
DUE TO IMPROPER SENSOR CLEARANCE. No Replace the ABS wheel-speed sensor, then go to Step 4.
• Inspect the clearance between the ABS (See 04-15-11 FRONT ABS WHEEL-SPEED SENSOR
wheel-speed sensor and the ABS sensor REMOVAL/INSTALLATION.)
rotor. (See 04-15-13 REAR ABS WHEEL-SPEED SENSOR
(See 04-15-12 FRONT ABS WHEEL- REMOVAL/INSTALLATION[2WD].)
SPEED SENSOR INSPECTION.) (See 04-15-13 REAR ABS WHEEL-SPEED SENSOR
(See 04-15-14 REAR ABS WHEEL-SPEED REMOVAL/INSTALLATION[AWD].)
SENSOR INSPECTION[2WD].)
(See 04-15-14 REAR ABS WHEEL-SPEED
SENSOR INSPECTION[AWD].)
• Is the clearance normal?
Clearance
Front: 0.7— 1.5 mm {0.028— 0.059 in}
Rear: 0.3— 1.1 mm {0.012— 0.043 in}
3 VISUALLY INSPECT ABS SENSOR ROTOR Yes Go to the next step.
FOR FOREIGN MATERIAL ADHERING OR No Replace the front drive shaft, rear wheel hub component
IMPROPER INSTALLATION (2WD) or rear drive shaft (AWD), then go to the next step.
• Is the result normal? (See 03-13-12 FRONT DRIVE SHAFT REMOVAL/
INSTALLATION.)
(See 03-12-3 WHEEL HUB COMPONENT REMOVAL/
INSTALLATION[2WD].)
(See 03-13-20 REAR DRIVE SHAFT REMOVAL/
INSTALLATION.)
4 VERIFY THAT THE SAME DTC IS NOT Yes Repeat the inspection from Step 1.
PRESENT If the malfunction recurs, replace the DSC HU/CM, then go
• Clear the DTC from the memory. to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.) (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Start the engine and drive the vehicle at 10 No Go to the next step.
km/h {6.2 mph} or more.
• Are the same DTCs present?
5 VERIFY THAT NO OTHER DTCS ARE Yes Go to the applicable DTC inspection.
PRESENT (See 04-02-3 ON-BOARD DIAGNOSIS.)
• Are any other DTCs output? No DTC troubleshooting completed.
End Of Sie
04-02–14
1871-1U-06B(04-02).fm 15 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
DTC C1145, C1155, C1165, C1175
id040200801100
RF
A M
ABS WHEEL-SPEED
SENSOR B O
LF
A F
ABS WHEEL-SPEED
SENSOR B E
DSC HU/CM
RR
A I
ABS WHEEL-SPEED
SENSOR B L
LR
A G
ABS WHEEL-SPEED
B H
SENSOR
AS AQ AO AM AK AI AG AE AC AA Y W U S Q O M K I G E
D C B A
AT AR AP AN AL AJ AH AF AD AB Z X V T R P N L J H F
B A B A
04-02–15
1871-1U-06B(04-02).fm 16 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PID TO VERIFY THAT WHEEL Yes Go to Step 3.
SPEED-SIGNALS ARE TRANSMITTED FROM No Go to the next step.
ABS WHEEL- SPEED SENSOR USING M-
MDS
• Turn the ignition switch off.
• Connect the M-MDS to the DLC-2.
• Select the following PIDs using the M-MDS:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
• Drive the vehicle.
• Verify that the wheel speed-signals are
transmitted from each ABS wheel-speed
sensor.
• Are the wheel-speed signals transmitted?
2 INSPECT FOR OPEN CIRCUIT IN WIRING Yes Replace the ABS wheel-speed sensor, then go to the next
HARNESS BETWEEN DSC HU/CM AND ABS step.
WHEEL-SPEED SENSOR (See 04-15-11 FRONT ABS WHEEL-SPEED SENSOR
• Turn the ignition switch off. REMOVAL/INSTALLATION.)
• Disconnect the DSC HU/CM connector and (See 04-15-13 REAR ABS WHEEL-SPEED SENSOR
ABS wheel-speed sensor. REMOVAL/INSTALLATION[2WD].)
• Inspect for continuity in the wiring harness (See 04-15-13 REAR ABS WHEEL-SPEED SENSOR
between the following ABS wheel-speed REMOVAL/INSTALLATION[AWD].)
sensor connectors on the vehicle wiring No Repair or replace the wiring harness, then go to the next
harness-side and DSC HU/CM connectors. step.
— RF ABS wheel-speed sensor: M— A
— RF ABS wheel-speed sensor: O— B
— LF ABS wheel-speed sensor: F— A
— LF ABS wheel-speed sensor: E— B
— RR ABS wheel-speed sensor: I— A
— RR ABS wheel-speed sensor: L— B
— LR ABS wheel-speed sensor: G— A
— LR ABS wheel-speed sensor: H— B
• Is there continuity?
3 VERIFY THAT THE SAME DTC IS NOT Yes Repeat the inspection from Step 1.
PRESENT If the malfunction recurs, replace the DSC HU/CM, then go
• Clear the DTCs from the memory. to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.) (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Start the engine and drive the vehicle at 10 No Go to the next step.
km/h {6.2 mph} or more.
• Are the same DTCs present?
4 VERIFY THAT NO OTHER DTCS ARE Yes Go to the applicable DTC inspection.
PRESENT (See 04-02-3 ON-BOARD DIAGNOSIS.)
• Are any other DTCs output? No DTC troubleshooting completed.
End Of Sie
04-02–16
1871-1U-06B(04-02).fm 17 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
DTC C1148, C1158, C1168, C1178
id040200801200
RF
A M
ABS WHEEL-SPEED 04-02
SENSOR B O
LF
A F
ABS WHEEL-SPEED
SENSOR B E
DSC HU/CM
RR
A I
ABS WHEEL-SPEED
SENSOR B L
LR
A G
ABS WHEEL-SPEED
B H
SENSOR
AS AQ AO AM AK AI AG AE AC AA Y W U S Q O M K I G E
D C B A
AT AR AP AN AL AJ AH AF AD AB Z X V T R P N L J H F
B A B A
04-02–17
1871-1U-06B(04-02).fm 18 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PID FOR ABNORMAL OUTPUT Yes Go to Step 4.
FROM ABS WHEEL-SPEED SENSOR USING No If there is a difference in speeds of the four wheels, go to the
M-MDS next step.
• Turn the ignition switch off.
• Connect the M-MDS to the DLC-2.
• Select the following PIDs using the M-MDS:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
• Start the engine and drive the vehicle.
• Verify that the PIDs of the four ABS wheel-
speed sensors correspond approximately.
• Do the vehicle speeds correspond?
2 INSPECT IF MALFUNCTION OCCURRED Yes Go to the next step.
DUE TO IMPROPER SENSOR CLEARANCE. No Replace the ABS wheel-speed sensor, then go to Step 4.
• Inspect the clearance between the ABS (See 04-15-11 FRONT ABS WHEEL-SPEED SENSOR
wheel-speed sensor and the ABS sensor REMOVAL/INSTALLATION.)
rotor. (See 04-15-13 REAR ABS WHEEL-SPEED SENSOR
(See 04-15-12 FRONT ABS WHEEL- REMOVAL/INSTALLATION[2WD].)
SPEED SENSOR INSPECTION.) (See 04-15-13 REAR ABS WHEEL-SPEED SENSOR
(See 04-15-14 REAR ABS WHEEL-SPEED REMOVAL/INSTALLATION[AWD].)
SENSOR INSPECTION[2WD].)
(See 04-15-14 REAR ABS WHEEL-SPEED
SENSOR INSPECTION[AWD].)
• Is the clearance normal?
Clearance
Front: 0.7— 1.5 mm {0.028— 0.059 in}
Rear: 0.3— 1.1 mm {0.012— 0.043 in}
3 VISUALLY INSPECT ABS SENSOR ROTOR Yes Go to the next step.
FOR FOREIGN MATERIAL ADHERING OR No Replace the front drive shaft, rear wheel hub component
IMPROPER INSTALLATION (2WD) or rear drive shaft (AWD), then go to the next step.
• Is the result normal? (See 03-13-12 FRONT DRIVE SHAFT REMOVAL/
INSTALLATION.)
(See 03-12-3 WHEEL HUB COMPONENT REMOVAL/
INSTALLATION[2WD].)
(See 03-13-20 REAR DRIVE SHAFT REMOVAL/
INSTALLATION.)
4 VERIFY THAT THE SAME DTC IS NOT Yes Repeat the inspection from Step 1.
PRESENT If the malfunction recurs, replace the DSC HU/CM, then go
• Clear the DTC from the memory. to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.) (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Start the engine and drive the vehicle at 10 No Go to the next step.
km/h {6.2 mph} or more.
• Are the same DTCs present?
5 VERIFY THAT NO OTHER DTCS ARE Yes Go to the applicable DTC inspection.
PRESENT (See 04-02-3 ON-BOARD DIAGNOSIS.)
• Are any other DTCs output? No DTC troubleshooting completed.
End Of Sie
04-02–18
1871-1U-06B(04-02).fm 19 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
DTC C1186, C1266
id040200801300
DSC HU/CM
C
ABS 2 20A 04-02
BATTERY
AS AQ AO AM AK AI AG AE AC AA Y W U S Q O M K I G E
D C B A
AT AR AP AN AL AJ AH AF AD AB Z X V T R P N L J H F
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DSC FUSE CONDITION Yes Go to the next step.
• Is the ABS 2 20A fuse normal? No Replace the fuse, then go to Step 3.
2 INSPECT VALVE RELAY POWER SUPPLY Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Turn the ignition switch off. between battery positive terminal and DSC HU/CM terminal
• Disconnect DSC HU/CM connector. C, then go to the next step.
• Turn the ignition switch to the ON position
(engine off).
• Measure voltage between DSC HU/CM
terminal C (harness-side) and ground.
• Is voltage B+?
3 VERIFY TROUBLESHOOTING COMPLETED Yes Replace the DSC HU/CM, then go to next step.
• Clear the DTC from the memory. (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
(See 04-02-3 ON-BOARD DIAGNOSIS.) No Go to the next step.
• Is the same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
04-02–19
1871-1U-06B(04-02).fm 20 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
DTC C1194, C1198, C1210, C1214, C1242, C1246, C1250, C1254, C1400, C1410, C1957, C1958
id040200801400
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY SOLENOID VALVE OPERATION Yes Go to the next step.
• Turn the ignition switch off. No Replace the DSC HU/CM, then go to the next step.
• Connect the M-MDS to the DLC-2. (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Turn the ignition switch to the ON position
(engine off).
• Access the active command mode for the
solenoid valve using the M-MDS.
• Does the solenoid valve operate?
2 VERIFY DTC TROUBLESHOOTING Yes Repeat the inspection from Step 1.
COMPLETED If the malfunction recurs, replace the DSC HU/CM, then go
• Clear the DTC from the memory. to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.) (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Start the engine and drive the vehicle at 10 No Go to the next step.
km/h {6.2 mph} or more.
• Gradually slow down and stop vehicle.
• Are the same DTCs present?
3 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
DTC C1222
id040200801500
Note
• DTC C1222 will be detected when a malfunctioning ABS wheel-speed sensor cannot be specified.
04-02–20
1871-1U-06B(04-02).fm 21 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
RF
A M
ABS WHEEL-SPEED
SENSOR B O
LF
A F
ABS WHEEL-SPEED
SENSOR B E
DSC HU/CM
RR
A I
ABS WHEEL-SPEED
SENSOR B L
LR
A G
ABS WHEEL-SPEED
B H
SENSOR
04-02
DSC HU/CM WIRING HARNESS-SIDE CONNECTOR
AS AQ AO AM AK AI AG AE AC AA Y W U S Q O M K I G E
D C B A
AT AR AP AN AL AJ AH AF AD AB Z X V T R P N L J H F
B A B A
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PID FOR ABS WHEEL-SPEED Yes Go to Step 4.
SENSOR OUTPUT ERROR USING M-MDS No Go to the next step.
• Turn the ignition switch off.
• Connect the M-MDS to the DLC-2.
• Select the following PIDs using the M-MDS:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
• Drive the vehicle.
• Verify that the vehicle speeds detected by
the four ABS wheel-speed sensors are
approximately the same.
• Are the vehicle speeds approximately the
same?
04-02–21
1871-1U-06B(04-02).fm 22 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT IF MALFUNCTION OCCURRED Yes Go to the next step.
DUE TO IMPROPER SENSOR CLEARANCE. No Replace the ABS wheel-speed sensor, then go to Step 4.
• Inspect the clearance between the ABS (See 04-15-11 FRONT ABS WHEEL-SPEED SENSOR
wheel-speed sensor and the ABS sensor REMOVAL/INSTALLATION.)
rotor. (See 04-15-13 REAR ABS WHEEL-SPEED SENSOR
(See 04-15-12 FRONT ABS WHEEL- REMOVAL/INSTALLATION[2WD].)
SPEED SENSOR INSPECTION.) (See 04-15-13 REAR ABS WHEEL-SPEED SENSOR
(See 04-15-14 REAR ABS WHEEL-SPEED REMOVAL/INSTALLATION[AWD].)
SENSOR INSPECTION[2WD].)
(See 04-15-14 REAR ABS WHEEL-SPEED
SENSOR INSPECTION[AWD].)
• Is the clearance normal?
Clearance
Front: 0.7— 1.5 mm {0.028— 0.059 in}
Rear: 0.3— 1.1 mm {0.012— 0.043 in}
3 VISUALLY INSPECT ABS SENSOR ROTOR Yes Go to the next step.
FOR FOREIGN MATERIAL ADHERING OR No Replace the front drive shaft, rear wheel hub component
IMPROPER INSTALLATION (2WD) or rear drive shaft (AWD), then go to the next step.
• Is the result normal? (See 03-13-12 FRONT DRIVE SHAFT REMOVAL/
INSTALLATION.)
(See 03-12-3 WHEEL HUB COMPONENT REMOVAL/
INSTALLATION[2WD].)
(See 03-13-20 REAR DRIVE SHAFT REMOVAL/
INSTALLATION.)
4 VERIFY THAT THE SAME DTC IS NOT Yes Repeat the inspection from Step 1.
PRESENT If the malfunction recurs, replace the DSC HU/CM, then go
• Clear the DTC from the memory. to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.) (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Start the engine and drive the vehicle at 10 No Go to the next step.
km/h {6.2 mph} or more.
• Are the same DTCs present?
5 VERIFY THAT NO OTHER DTCS ARE Yes Go to the applicable DTC inspection.
PRESENT (See 04-02-3 ON-BOARD DIAGNOSIS.)
• Are any other DTCs output? No DTC troubleshooting completed.
End Of Sie
DTC C1233, C1234, C1235, C1236
id040200801600
04-02–22
1871-1U-06B(04-02).fm 23 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
RF
A M
ABS WHEEL-SPEED
SENSOR B O
LF
A F
ABS WHEEL-SPEED
SENSOR B E
DSC HU/CM
RR
A I
ABS WHEEL-SPEED
SENSOR B L
LR
A G
ABS WHEEL-SPEED
B H
SENSOR
04-02
DSC HU/CM WIRING HARNESS-SIDE CONNECTOR
AS AQ AO AM AK AI AG AE AC AA Y W U S Q O M K I G E
D C B A
AT AR AP AN AL AJ AH AF AD AB Z X V T R P N L J H F
B A B A
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PID TO VERIFY THAT WHEEL Yes Go to Step 3.
SPEED-SIGNALS ARE TRANSMITTED FROM No Go to the next step.
ABS WHEEL- SPEED SENSOR USING M-
MDS
• Turn the ignition switch off.
• Connect the M-MDS to the DLC-2.
• Select the following PIDs using the M-MDS:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
• Drive the vehicle.
• Verify that the wheel speed-signals are
transmitted from each ABS wheel-speed
sensor.
• Are the wheel-speed signals transmitted?
04-02–23
1871-1U-06B(04-02).fm 24 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT FOR OPEN CIRCUIT IN WIRING Yes Replace the ABS wheel-speed sensor, then go to the next
HARNESS BETWEEN DSC HU/CM AND ABS step.
WHEEL-SPEED SENSOR (See 04-15-11 FRONT ABS WHEEL-SPEED SENSOR
• Turn the ignition switch off. REMOVAL/INSTALLATION.)
• Disconnect the DSC HU/CM connector and (See 04-15-13 REAR ABS WHEEL-SPEED SENSOR
ABS wheel-speed sensor. REMOVAL/INSTALLATION[2WD].)
• Inspect for continuity in the wiring harness (See 04-15-13 REAR ABS WHEEL-SPEED SENSOR
between the following ABS wheel-speed REMOVAL/INSTALLATION[AWD].)
sensor connectors on the vehicle wiring No Repair or replace the wiring harness, then go to the next
harness-side and DSC HU/CM connectors. step.
— RF ABS wheel-speed sensor: M— A
— RF ABS wheel-speed sensor: O— B
— LF ABS wheel-speed sensor: F— A
— LF ABS wheel-speed sensor: E— B
— RR ABS wheel-speed sensor: I— A
— RR ABS wheel-speed sensor: L— B
— LR ABS wheel-speed sensor: G— A
— LR ABS wheel-speed sensor: H— B
• Is there continuity?
3 VERIFY THAT THE SAME DTC IS NOT Yes Repeat the inspection from Step 1.
PRESENT If the malfunction recurs, replace the DSC HU/CM, then go
• Clear the DTCs from the memory. to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.) (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Start the engine and drive the vehicle at 10 No Go to the next step.
km/h {6.2 mph} or more.
• Are the same DTCs present?
4 VERIFY THAT NO OTHER DTCS ARE Yes Go to the applicable DTC inspection.
PRESENT (See 04-02-3 ON-BOARD DIAGNOSIS.)
• Are any other DTCs output? No DTC troubleshooting completed.
End Of Sie
DTC C1279, C1280, C1281, C1282, C1951, C1952, C1959, C2768
id040200801700
04-02–24
1871-1U-06B(04-02).fm 25 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
• Open circuit in the wiring harness between ignition switch and combined sensor terminal E or short
circuit to ground
• Open circuit in the wiring harness between DSC HU/CM terminal Y and combined sensor terminal F or
short circuit to ground
• Open circuit in the wiring harness between DSC HU/CM terminal AB and combined sensor terminal C
or short circuit to ground
POSSIBLE
• Open circuit in the wiring harness between DSC HU/CM terminal AE and combined sensor terminal A
CAUSE
or short circuit to ground
• Open circuit in the wiring harness between DSC HU/CM terminal AA and combined sensor terminal B
or short circuit to ground
• Open circuit in the wiring harness between DSC HU/CM terminal AI and combined sensor terminal D
• Combined sensor malfunction
• Poor connection at connectors (female terminal)
IG 1
04-02
E
Y F
DSC HU/CM
AB C COMBINED SENSOR
AE A
AA B
AI D
AS AQ AO AM AK AI AG AE AC AA Y W U S Q O M K I G E
D C B A
AT AR AP AN AL AJ AH AF AD AB Z X V T R P N L J H F
E C A
F D B
04-02–25
1871-1U-06B(04-02).fm 26 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT COMBINED SENSOR POWER Yes Go to the next step.
SUPPLY FOR OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Turn the ignition switch to the ON position between combined sensor terminal E and ignition switch,
(engine off). then go to Step 12.
• Measure voltage between combined sensor
terminal E (harness-side) and ground.
• Is the voltage B+?
2 INSPECT COMBINED SENSOR GROUND Yes Go to the next step.
FOR OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Turn the ignition switch off. between DSC HU/CM terminal Y and combined sensor
• Disconnect DSC HU/CM and combined terminal F, then go to Step 12.
sensor connectors.
• Inspect for continuity between DSC HU/CM
terminal Y (harness-side) and combined
sensor terminal F (harness-side).
• Is there continuity?
3 INSPECT COMBINED SENSOR (YAW RATE Yes Go to the next step.
PART) SIGNAL FOR OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Inspect for continuity between DSC HU/CM between DSC HU/CM terminal AA and combined sensor
terminal AA (harness-side) and combined terminal B, then go to Step 12.
sensor terminal B (harness-side).
• Is there continuity?
4 INSPECT COMBINED SENSOR (YAW RATE Yes Repair or replace the wiring harness for short to ground
PART) SIGNAL FOR SHORT TO GROUND between DSC HU/CM terminal AA and combined sensor
• Turn the ignition switch off. terminal B, then go to Step 12.
• Inspect for continuity between DSC HU/CM No Go to the next step.
terminal AA (harness-side) and ground.
• Is there continuity?
5 INSPECT COMBINED SENSOR (LATERAL-G Yes Go to the next step.
PART) SIGNAL FOR OPEN CIRCUIT No Repair or replace the wiring harness for open circuit
• Inspect for continuity between DSC HU/CM between DSC HU/CM terminal AI and combined sensor
terminal AI (harness-side) and combined terminal D, then go to Step 12.
sensor terminal D (harness-side).
• Is there continuity?
6 INSPECT COMBINED SENSOR (LATERAL-G Yes Repair or replace the wiring harness for short to ground
PART) SIGNAL FOR SHORT TO GROUND between DSC HU/CM terminal AI and combined sensor
• Turn the ignition switch off. terminal D, then go to Step 12.
• Inspect for continuity between DSC HU/CM No Go to the next step.
terminal AI (harness-side) and ground.
• Is there continuity?
7 INSPECT REFERENCE SIGNAL FOR OPEN Yes Go to the next step.
CIRCUIT No Repair or replace the wiring harness for open circuit
• Turn the ignition switch off. between DSC HU/CM terminal AE and combined sensor
• Inspect for continuity between DSC HU/CM terminal A, then go to Step 12.
terminal AE (harness-side) and combined
sensor terminal A (harness-side).
• Is there continuity?
8 INSPECT REFERENCE SIGNAL FOR SHORT Yes Repair or replace the wiring harness for short to ground
TO GROUND between DSC HU/CM terminal AE and combined sensor
• Turn the ignition switch off. terminal A, then go to Step 12.
• Inspect for continuity between DSC HU/CM No Go to the next step.
terminal AE (harness-side) and ground.
• Is there continuity?
9 INSPECT TEST SIGNAL FOR OPEN CIRCUIT Yes Go to the next step.
• Turn the ignition switch off. No Repair or replace the wiring harness for open circuit
• Inspect for continuity between DSC HU/CM between DSC HU/CM terminal AB and combined sensor
terminal AB (harness-side) and combined terminal C, then go to Step 12.
sensor terminal C (harness-side).
• Is there continuity?
04-02–26
1871-1U-06B(04-02).fm 27 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
10 INSPECT TEST SIGNAL FOR SHORT TO Yes Repair or replace the wiring harness for short to ground
GROUND between DSC HU/CM terminal AB and combined sensor
• Turn the ignition switch off. terminal C, then go to Step 12.
• Inspect for continuity between DSC HU/CM No Go to the next step.
terminal AB (harness-side) and ground.
• Is there continuity?
11 INSPECT COMBINED SENSOR Yes Go to the next step.
• Inspect the combined sensor. No Replace the combined sensor, then go to the next step.
(See 04-15-16 COMBINED SENSOR (See 04-15-15 COMBINED SENSOR REMOVAL/
INSPECTION.) INSTALLATION.)
• Is the combined sensor normal?
12 VERIFY DTC TROUBLESHOOTING Yes Replace the DSC HU/CM, then go to the next step.
COMPLETED. (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Clear the DTC from the memory. No Go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.) 04-02
• Are the same DTCs present?
13 VERIFY AFTER REPAIR PROCEDURE. Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
DTC C1288, C1290, C1953
id040200801800
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY NO ABNORMALITY ON BRAKE Yes Replace the DSC HU/CM, then go to the next step.
FLUID PRESSURE SENSOR (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Clear the DTCs from the memory. No Go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.)
• Start the engine and drive the vehicle at 10
km/h {6.2 mph} or more.
• Are the same DTCs present?
2 VERIFY THAT NO OTHER DTCS ARE Yes Go to the applicable DTC inspection.
PRESENT (See 04-02-3 ON-BOARD DIAGNOSIS.)
• Are any other DTCs output? No DTC troubleshooting completed.
End Of Sie
04-02–27
1871-1U-06B(04-02).fm 28 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
DTC C1295, C1307, C1937, C1938
id040200805000
STEERING
DSC HU/CM BCM ANGLE
CAN_H SENSOR
CAN X CAN
DRIVER W DRIVER
CAN_L
AS AQ AO AM AK AI AG AE AC AA Y W U S Q O M K I G E
D C B A
AT AR AP AN AL AJ AH AF AD AB Z X V T R P N L J H F
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT FOR BCM MALFUNCTION Yes Go to applicable DTC inspection.
• Turn the ignition switch off. (See 09-02F-2 DTC TABLE[BCM].)
• Using the M-MDS, perform the DTC No Go to the next step.
inspection for the BCM.
• Are any DTCs detected?
2 VERIFY DTC TROUBLESHOOTING Yes Replace the DSC HU/CM, then go to the next step.
COMPLETED (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Clear the DTC from the memory. No Go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.)
• Are the same DTCs present?
3 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
04-02–28
1871-1U-06B(04-02).fm 29 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
DTC C1306
id040200802000
Note
• The steering angle initialization value of the BCM is stored using the battery power supply. Therefore, the
battery power supply of the BCM is cut and the stored steering angle initialization value is cleared when
any of the following items are performed. DTC C1306 is stored in the memory.
— Negative battery cable disconnection
— BCM connector disconnection
— Fuse (ROOM) removal
— Wiring harness disconnection between battery and steering angle sensor connector
— Wiring harness disconnection between battery, BCM connector, steering angle sensor connector
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY INITIALIZATION PROCEDURE. Yes Go to the next step.
• Has the steering angle sensor initialization No Perform the steering angle sensor initialization procedure,
procedure been performed? then go to Step 3. (See 09-40-8 STEERING ANGLE
SENSOR INITIALIZATION PROCEDURE.)
2 INSPECT FOR BCM MALFUNCTION Yes Go to applicable DTC inspection.
• Turn the ignition switch off. (See 09-02F-2 DTC TABLE[BCM].)
• Using the M-MDS, perform the DTC No Go to the next step.
inspection for the BCM.
• Are any DTCs detected?
3 VERIFY DTC TROUBLESHOOTING Yes Repeat the inspection from Step 1.
COMPLETED If the malfunction occurs again, replace the DSC HU/CM,
• Clear the DTC from the memory. then go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.) (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Is the same DTC present? No Go to the next step.
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
04-02–29
1871-1U-06B(04-02).fm 30 ページ 2006年3月15日 水曜日 午前11時12分
ON-BOARD DIAGNOSTIC
DTC C1414
id040200805200
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY THAT THE CORRECT DSC HU/CM IS Yes Go to the next step.
INSTALLED No After replacing the DSC HU/CM, go to Step 3.
• Verify the part number of the DSC HU/CM. (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Is the part number correct?
2 CONFIGURE DSC HU/CM Yes Go to the next step.
• Can DSC HU/CM configure properly? No Replace the DSC HU/CM, then go to the next step.
(See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
3 VERIFY DTC TROUBLESHOOTING Yes Repeat the inspection from Step 1.
COMPLETED If the malfunction recurs, replace the DSC HU/CM, then go
• Make sure to reconnect all disconnected to the next step.
connectors. (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Clear the DTC from the memory. No Go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.)
• Is the same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
DTC C1994
id040200802200
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY DTC TROUBLESHOOTING Yes Replace the DSC HU/CM, then go to the next step.
COMPLETED (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
• Clear the DTC from the memory. No Go to the next step.
(See 04-02-3 ON-BOARD DIAGNOSIS.)
• Are the same DTCs present?
2 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Are any other DTCs present? (See 04-02-3 ON-BOARD DIAGNOSIS.)
No DTC troubleshooting completed.
End Of Sie
04-02–30
1871-1U-06B(04-03).fm 1 ページ 2006年3月15日 水曜日 午前11時12分
SYMPTOM TROUBLESHOOTING
04-03 SYMPTOM TROUBLESHOOTING
SYSTEM WIRING DIAGRAM . . . . . . . . . 04-03–2 NO.3 THERE IS A MALFUNCTION
FOREWORD . . . . . . . . . . . . . . . . . . . . . . 04-03–3 IN THE SYSTEM EVEN THOUGH
PRECAUTION . . . . . . . . . . . . . . . . . . . . . 04-03–3 ABS WARNING LIGHT, BRAKE SYSTEM
Intermittent Concern WARNING LIGHT, DSC INDICATOR
Troubleshooting . . . . . . . . . . . . . . . . . 04-03–4 LIGHT AND TCS OFF LIGHT DO NOT
SYMPTOM TROUBLESHOOTING . . . . . 04-03–6 ILLUMINATE. . . . . . . . . . . . . . . . . . . . . . 04-03–10
NO.1 ANY OF THE FOLLOWING NO.4 ABS OR TCS*1 OPERATES
LIGHTS DO NOT ILLUMINATE FREQUENTLY/TCS DOES NOT
WHEN IGNITION SWITCH TURNED WORK CORRECTLY*1:
TO ON POSITION: (ABS WARNING DSC SYSTEM FUNCTION CONTAINS
LIGHT, BRAKE SYSTEM WARNING TRACTION CONTROL FUNCTION, DSC
LIGHT, DSC INDICATOR LIGHT INDICATOR LIGHT GOES ON AND
AND/OR TCS OFF LIGHT) . . . . . . . . . . 04-03–8 OFF WHILE DSC IS OPERATING . . . . . 04-03–10
NO.2 ANY OF THE FOLLOWING NO.5 DSC*2 OPERATES 04-03
LIGHTS REMAIN ON: (ABS WARNING FREQUENTLY/DSC DOES NOT
LIGHT, BRAKE SYSTEM WARNING WORK CORRECTLY*2:
LIGHT, DSC INDICATOR LIGHT DSC INDICATOR LIGHT GOES ON
AND/OR TCS OFF LIGHT) . . . . . . . . . . 04-03–9 AND OFF WHILE DSC IS
OPERATING . . . . . . . . . . . . . . . . . . . . . . 04-03–11
End of Toc
WM: DYNAMIC STABILITY CONTROL
04-03–1
1871-1U-06B(04-03).fm 2 ページ 2006年3月15日 水曜日 午前11時12分
SYMPTOM TROUBLESHOOTING
SYSTEM WIRING DIAGRAM
id040300800100
ABS 2 20A
C IG 1
E
ABS 1 40A Y F
B AB C COMBINED
AE A SENSOR
AA B
AI D
A
DSC 7.5A
J
IG SW
BATTERY STEERING
BCM ANGLE
SENSOR
BRAKE SYSTEM ABS WARNING
WARNING LIGHT LIGHT
CAN_L
CAN_H
DSC HU/CM
DSC INDICATOR
LIGHT
CAN
DRIVER
CAN_H
INSTRUMENT CLUSTER X CAN
PCM W DRIVER
CAN_L
CAN BRAKE SWITCH
DRIVER N
TCM
CAN
DRIVER
TSC OFF SWITCH
P
DLC-2
CAN_L
CAN_H
RF M
O
LF F
E
ABS WHEEL-
SPEED SENSOR
RR I
L
LR G
H D
acxuuw00002205
End Of Sie
04-03–2
1871-1U-06B(04-03).fm 3 ページ 2006年3月15日 水曜日 午前11時12分
SYMPTOM TROUBLESHOOTING
FOREWORD
id040300800200
• Before performing the steps in Symptom Troubleshooting, perform the On-board Diagnostic Inspection. To
check the DTC, follow the DTC Inspection steps. (See 04-02-3 ON-BOARD DIAGNOSIS.)
End Of Sie
PRECAUTION
id040300800300
1. The ABS warning light and/or BRAKE system warning light and/or DSC indicator light and/or TCS OFF light
illuminate even when the system is normal.
Warning lights that may Condition under which the Conditions under which the ABS, EBD, TCS and DSC
illuminate and/or flash light may illuminate light will go out control
• ABS warning light Under any of the following After turning ignition switch • ABS: Disables control.
• BRAKE system warning conditions: off, vehicle is driven at speed • EBD:
light • When the front wheels are greater than 10 km/h {6.2 1. Disable control, in
• DSC indicator light jacked up, stuck, or placed mph} and normal operation is cases where the light
on a chassis roller, and confirmed. may illuminate, only
only the front wheel ABS when ABS HU/CM 04-03
wheel speed sensors are detects that wheel
spun for 20 s or more. speed sensors
Parking brake is not fully determine that two or
released while driving. more wheels are
malfunctioning.
Brake drag. 2. Enables control, if
Sudden wheel speed sensors
acceleration/deceleration. determine three or more
Left/right or front/rear tires are wheels are functioning
different. (Size, radius, tire correctly.
pressure, or wear is other than • TCS: Disables control.
that listed on tire label.) • DSC: Disables control.
Battery voltage at DSC HU/ Battery voltage rises above ABS: Disables control.
CM ignition terminal drops approx. 10 V. EBD: Enables control.
below approx. 10 V. TCS: Disables control.
DSC: Disables control.
• Brake system warning Brake fluid amount is low. Brake fluid level lower than ABS: Enables control.
light recommended amount. EBD: Enables control.
TCS: Enables control.
DSC: Enables control.
Caution
• In DSC vehicles, when the DSC HU/CM, steering angle sensor, or combined sensor is replaced,
perform the initialization procedure for each sensor. (See 09-40-8 STEERING ANGLE SENSOR
INITIALIZATION PROCEDURE.) (See 04-15-17 COMBINED SENSOR INITIALIZATION PROCEDURE.)
04-03–3
1871-1U-06B(04-03).fm 4 ページ 2006年3月15日 水曜日 午前11時12分
SYMPTOM TROUBLESHOOTING
• To protect the control module, make sure the ignition is off before connecting or disconnecting the
control module connector.
(2) Malfunctions in hydraulic system
• Symptoms in a hydraulic system malfunction are similar to those in a conventional brake malfunction.
However, it is necessary to determine if the malfunction is in a DSC component or the conventional
brake system.
• The hydraulic unit contains delicate mechanical parts. If foreign material gets into the component, the
DSC may fail to operate. Also, it will likely become extremely difficult to find the location of the
malfunction in the event that the brakes operate but the DSC does not. Make sure foreign material does
not enter when servicing the DSC (e.g.brake fluid replacement, pipe removal).
Note
• There are several reasons why vehicle or engine vibration could cause an electrical malfunction. Inspect
the following:
— Connectors not fully seated.
— Wire harnesses not having full play.
— Wires laying across brackets or moving parts.
— Wires routed too close to hot parts.
• An improperly routed, improperly clamped, or loose harness can cause wiring to become pinched
between parts.
• The connector joints, points of vibration, and places where wiring harnesses pass through the firewall,
body and other panels are the major areas to be inspected.
Note
• If the engine starts and runs, perform the following steps at idle.
acxuuw00000960
Note
• If the engine starts and runs, perform the following steps at idle.
04-03–4
1871-1U-06B(04-03).fm 5 ページ 2006年3月15日 水曜日 午前11時12分
SYMPTOM TROUBLESHOOTING
4. Slightly shake each connector or wiring harness
vertically and horizontally while monitoring the
PID.
• If the PID value is unstable, inspect for poor
connection.
acxuuw00000961
Note
• If engine starts and runs, perform the following steps at idle.
acxuuw00000962
04-03–5
1871-1U-06B(04-03).fm 6 ページ 2006年3月15日 水曜日 午前11時12分
SYMPTOM TROUBLESHOOTING
SYMPTOM TROUBLESHOOTING
id040300800400
• Verify the symptoms, and perform troubleshooting according to the appropriate number.
No. Symptom
1 Any of the following lights do not illuminate when the ignition switch is turned to the ON position.
• ABS warning light
• BRAKE system warning light
• DSC indicator light
• TCS OFF light
2 Any of the following lights remain on:
• ABS warning light.
• BRAKE system warning light
• DSC indicator light
• TCS OFF light
3 There is a malfunction in the system even though ABS warning light, BRAKE system warning light, DSC indicator
light and TCS OFF light do not illuminate.
4 ABS or TCS*1 operates frequently.
TCS does not work correctly.
5 DSC*2 operates frequently.
DSC does not work correctly.
*1
: DSC system contains traction control function; DSC indicator light illuminates and goes out while DSC is
operating.
*2
: DSC indicator light illuminates and goes out while DSC is operating.
04-03–6
1871-1U-06B(04-03).fm 7 ページ 2006年3月15日 水曜日 午前11時12分
SYMPTOM TROUBLESHOOTING
x: Applicable
Possible factor
Conventional brake
Instrument cluster
Charging system
Brake fluid
04-03
Battery
Tire
Troubleshooting item
1 Any of the following lights do not illuminate
when the ignition switch is turned to the on X X X X X
position: (ABS warning light, BRAKE system
warning light, DSC indicator light and/or TCS
OFF light).
2 Any of the following lights remain on: (ABS X X X X X X X X
warning light, BRAKE system warning light,
DSC indicator light and/or TCS OFF light).
*1: DSC system contains traction control function; DSC indicator light illuminates and goes out while DSC is
operating.
*2: DSC indicator light illuminates and goes out while DSC is operating.
acxuuw00000963
End Of Sie
04-03–7
1871-1U-06B(04-03).fm 8 ページ 2006年3月15日 水曜日 午前11時12分
SYMPTOM TROUBLESHOOTING
NO.1 ANY OF THE FOLLOWING LIGHTS DO NOT ILLUMINATE WHEN IGNITION SWITCH TURNED TO ON
POSITION: (ABS WARNING LIGHT, BRAKE SYSTEM WARNING LIGHT, DSC INDICATOR LIGHT AND/OR
TCS OFF LIGHT)
id040300803600
Any of the following lights do not illuminate when the ignition switch is turned to the ON position:
1
(ABS warning light, BRAKE system warning light, DSC indicator light and/or TCS OFF light).
[TROUBLESHOOTING HINTS]
• Inspect each light in the instrument cluster for malfunction
• Poor connection at DSC HU/CM connector
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT FOR DTCS IN DSC HU/CM Yes Perform the applicable DTC inspection.
• Inspect the DTC for the DSC ON-BOARD (See 04-02-3 ON-BOARD DIAGNOSIS.)
DIAGNOSTIC SYSTEM. No Go to the next step.
• Have DTCs been stored in memory?
2 INSPECT WHETHER MALFUNCTION IS IN Yes Go to the next step.
INSTRUMENT CLUSTER SYSTEM OR OTHER No Inspect or repair the instrument cluster (power supply
SYSTEM system, ground system).
• Do other warning and indicator lights
illuminate when the ignition switch is turned
to the ON position?
3 VERIFY THAT DSC HU/CM CONNECTOR IS Yes Go to the next step.
CONNECTED No Connect the DSC HU/CM connector securely, then go to the
• Is the DSC HU/CM securely connected? next step.
4 VERIFY THAT DSC HU/CM CONNECTOR Yes Go to the next step.
TERMINAL OR RELATED CONNECTOR No Securely connect the DSC HU/CM connector terminal and
TERMINALS ARE CONNECTED related connector terminals.
• Are DSC HU/CM connector terminal,
instrument cluster connector terminal, or
related connector terminals securely
connected?
5 INSPECT INSTRUMENT CLUSTER Yes Replace the DCS HU/CM.
• Inspect the instrument cluster. (see 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
(See 04-02-3 ON-BOARD DIAGNOSIS.) No Replace the instrument cluster.
• If the instrument cluster normal (See 04-02-3 ON-BOARD DIAGNOSIS.)
End Of Sie
04-03–8
1871-1U-06B(04-03).fm 9 ページ 2006年3月15日 水曜日 午前11時12分
SYMPTOM TROUBLESHOOTING
NO.2 ANY OF THE FOLLOWING LIGHTS REMAIN ON: (ABS WARNING LIGHT, BRAKE SYSTEM WARNING
LIGHT, DSC INDICATOR LIGHT AND/OR TCS OFF LIGHT)
id040300803700
Any of the following lights remain on: (ABS warning light, BRAKE system warning light, DSC
2
indicator light and/or TCS OFF light)
[TROUBLESHOOTING HINTS]
• Brake fluid amount is low
• Parking brake does not release
• No connection at DSC HU/CM connector
(When DSC HU/CM connector is disconnected, ABS warning light and BRAKE system warning light illuminate)
• DSC HU/CM detected malfunction (Input and output device malfunction)
• DSC HU/CM detects low voltage in power supply
• DSC HU/CM ground malfunction
(When DSC HU/CM ground is not securely connected, ABS warning light and BRAKE system warning light
illuminate but diagnostic trouble code does not displayed)
• DSC HU/CM does not operate (DSC HU/CM malfunction)
04-03
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT BRAKE FLUID AMOUNT AND Yes Go to the next step.
VERIFY THAT PARKING BRAKE RELEASES No Add brake fluid or release parking brake lever.
• Is the brake fluid amount normal?
• Is the parking brake lever released?
2 INSPECT DTCS IN INSTRUMENT CLUSTER Yes Go to the next step.
• Inspect the DTC for the instrument cluster No Inspect the instrument cluster.
ON-BOARD DIAGNOSTIC SYSTEM. (See 09-22-3 INSTRUMENT CLUSTER INSPECTION.)
• Has DTC U2064 been recorded in memory?
3 INSPECT DTCS IN DSC HU/CM Yes Perform inspection using appropriate DTC.
• Inspect the DTC for the DSC ON-BOARD (See 04-02-3 ON-BOARD DIAGNOSIS.)
DIAGNOSTIC SYSTEM. No Go to the next step.
• Have DTCs been stored in memory?
4 INSPECT WHETHER MALFUNCTION IS IN Yes Temporary poor connection in control module connector.
CONTROL MODULE CONNECTOR, Inspect DSC HU/CM connector, then go to Step 7.
TERMINAL OR OTHER Inspect DSC HU/CM connector terminal, then go to Step 8.
• Do the ABS warning light and BRAKE No Go to the next step.
system warning light go out after 4 s when
the ignition switch is turned to the ON
position?
5 INSPECT BATTERY Yes Go to the next step.
• Is the battery voltage normal? No Inspect the battery and charging system.
(See 01-17-2 BATTERY INSPECTION[L3 WITH TC].)
(See 01-17-6 GENERATOR INSPECTION[L3 WITH TC].)
6 INSPECT CHARGING SYSTEM Yes Go to the next step.
• Is the battery voltage normal with electrical No Inspect the charging system (drive belt tension, generator,
load (A/C, headlight, etc.) on and engine etc.).
idling? (See 01-17-6 GENERATOR INSPECTION[L3 WITH TC].)
7 VERIFY THAT DSC HU/CM CONNECTOR IS Yes Go to the next step.
CONNECTED No Connect the DSC HU/CM connector securely, then go to the
• Is the DSC HU/CM securely connected? next step.
8 VERIFY THAT DSC HU/CM CONNECTOR Yes Replace the DSC HU/CM.
TERMINAL OR RELATED CONNECTOR (See 04-15-6 DSC HU/CM REMOVAL/INSTALLATION.)
TERMINALS ARE CONNECTED No Securely connect the DSC HU/CM connector terminal and
• Are the DSC HU/CM connector terminal or related connector terminals.
instrument cluster connector terminal etc.
related connector terminals securely
connected?
End Of Sie
04-03–9
1871-1U-06B(04-03).fm 10 ページ 2006年3月15日 水曜日 午前11時12分
SYMPTOM TROUBLESHOOTING
NO.3 THERE IS A MALFUNCTION IN THE SYSTEM EVEN THOUGH ABS WARNING LIGHT, BRAKE SYSTEM
WARNING LIGHT, DSC INDICATOR LIGHT AND TCS OFF LIGHT DO NOT ILLUMINATE
id040300803800
There is a malfunction in the system even though the ABS warning light, BRAKE system warning
3
light, DSC indicator light and TCS OFF light do not illuminate.
[TROUBLESHOOTING HINTS]
• There is a mechanical malfunction in system
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DSC HU/CM FOR DTCs Yes Perform the applicable DTC inspection.
• Inspect the DTC for the DSC ON-BOARD (See 04-02-3 ON-BOARD DIAGNOSIS.)
DIAGNOSTIC SYSTEM. No Go to the next step.
• Have DTCs been stored in memory?
2 INSPECT DSC SYSTEM Yes Inspect the conventional brake system.
• Perform DSC system inspection. No Repair or replace any malfunctioning part.
(See 04-15-4 DSC SYSTEM INSPECTION.)
• Is the system normal?
End Of Sie
NO.4 ABS OR TCS*1 OPERATES FREQUENTLY/TCS DOES NOT WORK CORRECTLY*1: DSC SYSTEM
FUNCTION CONTAINS TRACTION CONTROL FUNCTION, DSC INDICATOR LIGHT GOES ON AND OFF
WHILE DSC IS OPERATING
id040300803400
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DTCS IN DSC HU/CM Yes Perform the applicable DTC inspection.
• Inspect the DTC for the DSC ON-BOARD (See 04-02-3 ON-BOARD DIAGNOSIS.)
DIAGNOSTIC SYSTEM. No Go to the next step.
• Have DTCs been stored in memory?
2 INSPECT TIRE SIZE AND AIR PRESSURE Yes Go to the next step.
• Inspect the tire size and the air pressure. No Replace with specified tires and adjust tire air pressure.
• Are size and air pressure as specified?
3 INSPECT ABS WHEEL-SPEED SENSOR Yes Go to the next step.
OUTPUT VALUE No • ABS wheel-speed sensor installation inspection:
• Inspect the output value from the ABS Inspect the sensor for looseness and verify that it is
wheel-speed sensor. securely installed.
(See 04-15-12 FRONT ABS WHEEL-SPEED • Sensor rotor installation inspection:
SENSOR INSPECTION.) Inspect the sensor rotor for poor installation and
(See 04-15-14 REAR ABS WHEEL-SPEED chipping of sensor rotor teeth. (If sensor rotor is installed
SENSOR INSPECTION[2WD].) poorly, it may cause output of abnormal wave form at
(See 04-15-14 REAR ABS WHEEL-SPEED high speed.)
SENSOR INSPECTION[AWD].)
• Is the output value normal?
4 VERIFY THAT TIRE CONDITION Yes Find malfunctioning part according to "INTERMITTENT
• Verify tire condition for following: CONCERN TROUBLESHOOTING".
— Wear No Adjust, repair or replace tire.
— Grip level (different by four wheels)
• Are tires condition okay?
End Of Sie
04-03–10
1871-1U-06B(04-03).fm 11 ページ 2006年3月15日 水曜日 午前11時12分
SYMPTOM TROUBLESHOOTING
NO.5 DSC*2 OPERATES FREQUENTLY/DSC DOES NOT WORK CORRECTLY*2: DSC INDICATOR LIGHT
GOES ON AND OFF WHILE DSC IS OPERATING
id040300803500
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DSC HU/CM FOR DTCs Yes Perform the applicable DTC inspection.
• Inspect the DTC for the DSC ON-BOARD (See 04-02-3 ON-BOARD DIAGNOSIS.)
DIAGNOSTIC SYSTEM. No Go to the next step.
• Have DTCs been recorded in memory?
2 VERIFY THAT EACH SENSOR IS INSTALLED Yes Go to the next step.
• Are the combined sensor and steering angle No Install sensor securely.
sensor securely installed?
*3 VERIFY THAT EACH SENSOR IS INITIALIZED Yes Go to the next step.
• Was initialization performed after No Perform initialization procedure.
replacement of the DSC HU/CM, combined (See 04-15-17 COMBINED SENSOR INITIALIZATION
sensor or steering angle sensor? PROCEDURE.)
(See 09-40-8 STEERING ANGLE SENSOR
INITIALIZATION PROCEDURE.)
4 VERIFY THAT TIRE CONDITION Yes Find malfunctioning part according to "INTERMITTENT
• Verify tire condition for following: CONCERN TROUBLESHOOTING".
— Air pressure No Adjust, repair or replace tire.
— Wear
— Grip level (different by four wheels)
• Are tires condition okay?
End Of Sie
04-03–11
1871-1U-06B(04-10).fm 1 ページ 2006年3月15日 水曜日 午前11時13分
GENERAL PROCEDURES
04-10 GENERAL PROCEDURES
GENERAL PROCEDURES (BRAKE) . . . 04-10–1 DSC Related Parts . . . . . . . . . . . . . . . . 04-10–1
Wheel and Tire Installation . . . . . . . . . 04-10–1 DSC Related Part Sensor
Brake Lines Disconnection. . . . . . . . . . 04-10–1 Initialization Procedure . . . . . . . . . . . . 04-10–1
Brake Pipe Flare Nut Tightening . . . . . 04-10–1 Steering Angle Sensor
Connector Disconnection . . . . . . . . . . . 04-10–1 Initialization Procedure . . . . . . . . . . . . 04-10–2
End of Toc
GENERAL PROCEDURES (BRAKE)
WM: BRAKES
id041000800100
Wheel and Tire Installation
1. When installing the wheels and tires, tighten the
wheel nuts in a criss-cross pattern to the following
tightening torque. 04-10
Tightening torque 1
88.2— 117.6 N·m {9.00— 11.99 Kgf·m, 4 3
65.06— 86.73 ft·lbf}
2 5
acxuuw00000002
Caution
• Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is
spilled, wipe it off immediately.
Connector Disconnection
1. Disconnect the negative battery cable before performing any work that requires handling of connectors. (See
01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].)
Warning
• If the initialization procedure is not completed, the DSC will not operate properly and it might
cause an unexpected accident. Therefore, when replacing or removing the following parts, make
sure to perform the initialization procedure to insure proper DSC operation.
1. When replacing or removing the following parts, perform the initialization procedure. (See 04-15-17
COMBINED SENSOR INITIALIZATION PROCEDURE.)
• DSC HU/CM
• Combined sensor
04-10–1
1871-1U-06B(04-10).fm 2 ページ 2006年3月15日 水曜日 午前11時13分
GENERAL PROCEDURES
Steering Angle Sensor Initialization Procedure
Warning
• Unless the initialization procedure of the steering angle sensor is completed, the DSC will not
operate, causing an unexpected accident. Therefore, always perform the initialization procedure to
ensure DSC operation if the power supply to the BCM has been cut off due to disconnection of the
BCM connector or negative battery cable, or any other cause.
Caution
• The steering angle sensor initialization value of the BCM is stored using the battery power supply.
Therefore, the battery power supply of the BCM is cut and the stored steering angle initialization
value is cleared when any of the following items are performed.
— Negative battery cable disconnection
— BCM connector disconnection
— Steering angle sensor connector disconnection
— Fuse (ROOM) removal
— Wiring harness disconnection between battery, BCM connector, steering angle sensor
connector
• If the initialization procedure for the steering angle sensor has not been performed, when the
ignition switch is turned to the ON position, the DSC indicator light illuminates and the TCS OFF
light flashes to warn of a malfunction.
1. When replacing or removing the following parts, perform the initialization procedure. (See 09-40-8 STEERING
ANGLE SENSOR INITIALIZATION PROCEDURE.)
• Negative battery cable disconnection
• BCM connector disconnection
• Steering angle sensor connector disconnection
• Fuse (ROOM) removal
• Wiring harness disconnection between battery, BCM connector, steering angle sensor connector
End Of Sie
04-10–2
1871-1U-06B(04-11).fm 1 ページ 2006年3月15日 水曜日 午前11時13分
End of Toc
WM: BRAKES
04-11–1
1871-1U-06B(04-11).fm 2 ページ 2006年3月15日 水曜日 午前11時13分
2WD
7
1
2 6
4
3
5
AWD
9
8
acxuuw00001738
End Of Sie
WM: CONVENTIONAL BRAKE SYSTEM
04-11–2
1871-1U-06B(04-11).fm 3 ページ 2006年3月15日 水曜日 午前11時13分
Caution
• Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is
spilled, wipe it off immediately.
Note
• Keep the fluid level in the reserve tank at 3/4 full or more during the air bleeding.
• Begin air bleeding with the brake caliper that is furthest from the master cylinder.
1. Remove the bleeder cap on the brake caliper, and attach a vinyl tube to the bleeder screw.
2. Place the other end of the vinyl tube in a clear container and fill the container with fluid during air bleeding.
3. Working with two people, one should pump the brake pedal several times and depress and hold the pedal 04-11
down.
4. While the brake pedal is depressed, the other 49 0259 770B
should loosen the bleeder screw using the SST,
drain out any fluid containing air bubbles, and
tighten the bleeder screw.
Tightening torque
Front: 5.9— 9.8 N·m {61— 99 kgf·cm, 53— 86
in·lbf}
Rear: 6.9— 9.8 N·m {71— 99 kgf·cm, 61— 86
in·lbf}
id041100801500
1. Remove the vacuum hose. (See 04-11-4 VACUUM HOSE REMOVAL/INSTALLATION.)
2. Verify that air can be blown from the power brake
unit side of the vacuum hose towards the engine
side, and that air cannot be blown in the opposite
direction.
• If there is any malfunction of the inner check
valve, replace it together with the vacuum
hose as a single unit. CHECK VALVE
End Of Sie
TO INTAKE MANIFOLD
acxuuw00001745
04-11–3
1871-1U-06B(04-11).fm 4 ページ 2006年3月15日 水曜日 午前11時13分
acxuuw00001109
JOINT
acxuuw00001110
acxuuw00001740
04-11–4
1871-1U-06B(04-11).fm 5 ページ 2006年3月15日 水曜日 午前11時13分
Note
• If there is no malfunction in the clevis pin, there is a possibility that the power brake unit has some
malfunction. Verify that there are no malfunctions, and replace it if necessary.
End Of Sie
FLOOR
COVERING
PEDAL-TO-FLOOR
CLEARANCE
acxuuw00001741
04-11–5
1871-1U-06B(04-11).fm 6 ページ 2006年3月15日 水曜日 午前11時13分
Caution
• The clearance between the brake switch and the brake pedal is automatically adjusted to the
correct amount when the brake switch is inserted into the installation hole on the brake pedal and
rotated to fix in place. If the brake switch is not properly installed, the clearance may be incorrect,
causing a brake light malfunction. Therefore, always verify that the brake pedal is properly
installed and fully released before installing the brake switch to the pedal.
• Once the brake switch clearance has automatically been adjusted, it cannot be adjusted again.
Therefore, replace the switch with a new one when replacing the power brake unit or the pedal, or
performing any procedure that changes the pedal stroke.
1. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].)
2. Remove the battery tray bracket as shown in the
figure.
3. Disconnect the brake fluid level sensor connector.
4. Remove the master cylinder reserve tank bracket
installation nuts. (See 04-11-10 MASTER BATTERY TRAY BRACKET
CYLINDER REMOVAL/INSTALLATION.)
5. Remove the accelerator pedal. (See 01-13-17
ACCELERATOR PEDAL REMOVAL/
INSTALLATION[L3 WITH TC].)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
18—26 N·m
{1.9—2.6 kgf·m,
14—19 ft·lbf}
acxuuw00001908
6 8
5
A B
B
7
4 A
18.6—25.5
{1.90—2.60,
13.8—18.8}
18.6—25.5 7 9
{1.90—2.60, C
13.8—18.8}
R 2
1
3
C
04-11–6
1871-1U-06B(04-11).fm 7 ページ 2006年3月15日 水曜日 午前11時13分
15.7—22.5
{1.61—2.29,
11.6—16.5}
15.7—22.5
15.7—22.5
{1.61—2.29,
{1.61—2.29, 11.6—16.5}
15.7—22.5 11.6—16.5}
{1.61—2.29,
11.6—16.5}
acxuuw00001563
04-11–7
1871-1U-06B(04-11).fm 8 ページ 2006年3月15日 水曜日 午前11時13分
Caution
• If the dashboard is moved towards the
vehicle rear excessively, the wiring DASHBOARD
harness could be damaged. Mark the BRACKET
position and verify the distance when
moving the dashboard.
20 mm {0.78 in}
acxuuw00001861
BRAKE SWITCH
LOCK UNIT
acxuuw00001744
04-11–8
1871-1U-06B(04-11).fm 9 ページ 2006年3月15日 水曜日 午前11時13分
Caution
• Inspect the brake switch with it installed to the brake pedal, otherwise the brake switch may not
operate normally. If the brake switch is removed from the brake pedal, replace the brake switch
with a new one.
acxuuw00001093
End Of Sie
WM: MASTER CYLINDER
04-11–9
1871-1U-06B(04-11).fm 10 ページ 2006年3月15日 水曜日 午前11時13分
4.2—6.2 2
{43—63, 38—54}
7
A
7.8—12.7
6 {80—129, 70—112}
3 C*
12.8—21.6
8 {131—220,
114—191}
A
B 10
9
R
12
B
11
4
7.8—12.7
{80—129, 70—112}
9.8—16 {100—163, 87—141}
acxuuw00001862
End Of Sie
04-11–10
1871-1U-06B(04-11).fm 11 ページ 2006年3月15日 水曜日 午前11時13分
: Continuity
Terminal
Condition
A B
acxuuw00001089
End Of Sie
POWER BRAKE UNIT INSPECTION
WM: POWER BRAKE UNIT
id041100801700
Note
• The following inspection methods are simple inspection methods to judge the function of the power brake
unit.
• If there is any malfunction in the power brake unit, replace the power brake unit as a single unit.
04-11–11
1871-1U-06B(04-11).fm 12 ページ 2006年3月15日 水曜日 午前11時13分
TO MASTER
CYLINDER
acxuuw00001746
49 N043 001
49 U043 005
acxuuw00001863
End Of Sie
04-11–12
1871-1U-06B(04-11).fm 13 ページ 2006年3月15日 水曜日 午前11時13分
04-11
18—26 N·m
{1.9—2.6 kgf·m,
14—19 ft·lbf}
acxuuw00001901
A * 12.8—21.6 N·m
{131—220 kgf·cm,
114—191 in·lbf}
04-11–13
1871-1U-06B(04-11).fm 14 ページ 2006年3月15日 水曜日 午前11時13分
4 2 R B
5
1 A
B
A
18.6—25.5 N·m
{1.90—2.60 kgf·m,
13.8—18.8 ft·lbf}
acxuuw00001091
End Of Sie
FRONT BRAKE (DISC) INSPECTION
WM: FRONT BRAKE (DISC)
id041100800800
Brake Judder Repair Hint
Description
Brake judder concern has the following three characteristics:
Floor vibration
When applying brakes, the vehicle body shakes back and forth. The seriousness of shake is not influenced by
vehicle speed.
Due to an excessive runout (side-to-side wobble) of disc plate, the thickness of disc plate is uneven.
If the runout is more than 0.05 mm {0.002 in} at the position 10 mm {0.39 in} from the disc plate edge, uneven
wear occurs on the disc plate because of uneven pad/plate contact.
If the runout is less than 0.05 mm {0.002 in}, uneven wear does not occur.
04-11–14
1871-1U-06B(04-11).fm 15 ページ 2006年3月15日 水曜日 午前11時13分
Due to corrosion, the thickness and friction coefficient of disc plate change.
If a vehicle is parked under damp conditions for a long time, corrosion occurs on the friction surface of disc plate.
The thickness of corrosion is uneven and sometimes appears like a wave pattern, which changes the friction
coefficient and causes a reaction force.
,
Confirm customer s complaint
04-11
Perform lateral runout inspection. More than 0.05 mm {0.002 in}
(Refer to Lateral Runout Inspection.)
Less than Less than
0.05 mm 0.05 mm
{0.002 in} Occurs {0.002 in}
Verify whether brake Remove disc plate and
Does not judder occurs or not. reinstall in other phase.
occur Perform lateral runout
Perform thickness variation inspection again.
inspection (Refer to the More than 0.015 mm {0.0005 in}
following.) More than
Less than 0.015 mm {0.0005 in} 0.05 mm
{0.002 in}
Confirm customer's complaint again.
Machine the disc plate using
Work is completed. on-the-car type lathe.
Work is completed.
acxuuw00001079
Note
• The component parts of the SST (49 B017 001 or 49 G019 003) can be used as a suitable washer.
2. After tightening all the hub nuts to the same torque, put the dial gauge on the friction surface of disc plate 10
mm {0.39 in} from the disc plate edge.
3. Rotate the disc plate one time and measure the runout.
04-11–15
1871-1U-06B(04-11).fm 16 ページ 2006年3月15日 水曜日 午前11時13分
Warning
• Do not exceed minimum disc plate
thickness.
acxuuw00001386
Caution
• Excessive runout may result if the disc plate is removed from the vehicle then machined. Machine
the disc plate while installed on the vehicle.
Minimum front disc plate thickness after machining using a brake lathe on-vehicle
26.8 mm {1.06 in}
End Of Sie
ampjjw00003083
04-11–16
1871-1U-06B(04-11).fm 17 ページ 2006年3月15日 水曜日 午前11時13分
B
5 C
R
C 10 R
D
7
6 6 9.8—14.7 N·m 11
4 {100—149 kgf·cm,
GREASE
87—130 in·lbf}
GREASE
A 10 A
GREASE
A R 7 9 4
ANTI-RATTLE
GREASE
A
GREASE
GREASE
BRAKE GREASE
B A
GREASE
acxuuw00001081
acxuuw00001082
04-11–17
1871-1U-06B(04-11).fm 18 ページ 2006年3月15日 水曜日 午前11時13分
2 SST
GREASE
1
83.3—93.1
5 {8.50—9.49,
4 61.5—68.6}
6 A
GREASE
A
GREASE
ANTI-RATTLE 6
GREASE
acxuuw00001078
End Of Sie
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY
WM: CALIPER (FRONT)
id041100801000
1. Disassemble in the order indicated in the table.
SST *5.9—9.8 {61—99, 53—86}
1 Bleeder cap
1 2 6
2 Bleeder screw
R BRAKE
FLUID
3 Piston
(See 04-11-19 Piston Disassembly Note.)
5 SST
4 Dust seal 3 R
5 Piston seal 4
6 Caliper
RUBBER GREASE
GREASE
04-11–18
1871-1U-06B(04-11).fm 19 ページ 2006年3月15日 水曜日 午前11時13分
Warning
• When compressed air is blown into the caliper body, injury to a finger or other part from pinching
could result from the piston springing up. When blowing in compressed air, do not place your
fingers between the piston and caliper body when performing the work.
Caution
• The piston could be damaged if blown out with great force. Blow the compressed air slowly to
prevent the piston from suddenly popping out.
acxuuw00001887
Floor vibration
When applying brakes, the vehicle body shakes back and forth. The seriousness of shake is not influenced by
vehicle speed.
Due to an excessive runout (side-to-side wobble) of disc plate, the thickness of disc plate is uneven.
If the runout is more than 0.05 mm {0.002 in} at the position 10 mm {0.39 in} from the disc plate edge, uneven
wear occurs on the disc plate because of uneven pad/plate contact.
If the runout is less than 0.05 mm {0.002 in}, uneven wear does not occur.
Due to corrosion, the thickness and friction coefficient of disc plate change.
If a vehicle is parked under damp conditions for a long time, corrosion occurs on the friction surface of disc plate.
The thickness of corrosion is uneven and sometimes appears like a wave pattern, which changes the friction
coefficient and causes a reaction force.
04-11–19
1871-1U-06B(04-11).fm 20 ページ 2006年3月15日 水曜日 午前11時13分
,
Confirm customer s complaint
Work is completed.
acxuuw00001070
Note
• The component parts of the SST (49 B017 001 or 49 G019 003) can be used as a suitable washer.
2. After tightening all the hub nuts to the same torque, put the dial gauge on the friction surface of disc plate 10
mm {0.39 in} from the disc plate edge.
3. Rotate the disc plate one time and measure the runout.
04-11–20
1871-1U-06B(04-11).fm 21 ページ 2006年3月15日 水曜日 午前11時13分
Warning
• Do not exceed minimum disc plate
thickness.
04-11
acxuuw00001385
Caution
• Excessive runout may result if the disc plate is removed from the vehicle then machined. Machine
the disc plate while installed on the vehicle.
Minimum rear disc plate thickness after machining using a brake lathe on-vehicle
16.8 mm {0.66 in}
End Of Sie
acxuuw00001654
04-11–21
1871-1U-06B(04-11).fm 22 ページ 2006年3月15日 水曜日 午前11時13分
GREASE
78.4—101.9 9 R
{8.00—10.39, 7
57.9—75.1} R 11
1 5
R
4
2
21.6—31.4 8
{2.21—3.20,
16.0—23.1}
10 R A 6
14
GREASE
9.8—14.7 N·m
{100—149 kgf·cm,
87—130 in·lbf}
13
4
12 5
GREASE
RUBBER GREASE
N·m {kgf·m, ft·lbf}
acxuuw00001739
04-11–22
1871-1U-06B(04-11).fm 23 ページ 2006年3月15日 水曜日 午前11時13分
04-11
acxuuw00001072
Disc Plate, Screw Installation Note
1. Install the disc plate and the screws.
2. Perform the following steps to adjust the shoe clearance after installing the disc plate and the screws.
(1) Insert a flathead screwdriver into the service
hole and turn the adjuster in the direction of
the arrow to expand the parking brake shoe
until the disc plate cannot rotate.
acxuuw00001073
(2) Return the adjuster 13—17 notches in the
direction of the arrow.
Note
• Shoe clearance can be adjusted to 0.15 mm
{0.006 in} by returning the adjuster 15
notches.
04-11–23
1871-1U-06B(04-11).fm 24 ページ 2006年3月15日 水曜日 午前11時13分
49 0221 600C
acxuuw00001075
acxuuw00001931
End Of Sie
WM: CALIPER (REAR)
04-11–24
1871-1U-06B(04-11).fm 25 ページ 2006年3月15日 水曜日 午前11時13分
GREASE
BRAKE
FLUID
GREASE
04-11
GREASE
RUBBER GREASE
Warning
• When compressed air is blown into the caliper body, injury to a finger or other part from pinching
could result from the piston springing up. When blowing in compressed air, do not place your
fingers between the piston and caliper body when performing the work.
Caution
• The piston could be damaged if blown out with great force. Blow the compressed air slowly to
prevent the piston from suddenly popping out.
acxuuw00001077
04-11–25
1871-1U-06B(04-12).fm 1 ページ 2006年3月15日 水曜日 午前11時15分
End of Toc
PARKING BRAKE SYSTEM LOCATION INDEX
WM: PARKING BRAKE SYSTEM
id041200800100
acxuuw00001756
End Of Sie
WM: PARKING BRAKE
04-12–1
1871-1U-06B(04-12).fm 2 ページ 2006年3月15日 水曜日 午前11時15分
Parking brake pedal stroke when depressed at 180 N {18.4 kgf, 40.5 lbf}
1— 3 notches
End Of Sie
PARKING BRAKE ADJUSTMENT
id041200800400
1. Start the engine and depress the parking brake pedal several times.
2. Stop the engine.
3. Turn the adjusting nut at the front of the parking
cable.
4. After adjustment, inspect the following points:
(1) Turn the ignition switch on, depress the
parking brake pedal one notch, and verify that
the brake system warning light illuminates.
ADJUSTING NUT
(2) Verify that the rear brakes do not drag.
End Of Sie
acxuuw00001058
04-12–2
1871-1U-06B(04-12).fm 3 ページ 2006年3月15日 水曜日 午前11時15分
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. Perform the following procedure and remove the parking brake pedal.
(1) Remove the lower panel. (See 09-17-9 LOWER PANEL REMOVAL/INSTALLATION.)
2. Perform the following procedure and remove the front parking brake cable.
(1) Remove the lower panel. (See 09-17-9 LOWER PANEL REMOVAL/INSTALLATION.)
(2) Remove the joint cover. (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(3) Remove the console panel. (See 09-17-15 CONSOLE PANEL REMOVAL/INSTALLATION.)
(4) Remove the console. (See 09-17-13 CONSOLE REMOVAL/INSTALLATION.)
(5) Remove the console bracket as shown in the 04-12
figure.
(6) Turn the floor covering over until the front
parking brake cable cover appears.
CONSOLE BRACKET
acxuuw00001866
acxuuw00001867
04-12–3
1871-1U-06B(04-12).fm 4 ページ 2006年3月15日 水曜日 午前11時15分
1 18.6—25.5
18.6—25.5
A {1.90—2.60,
{1.90—2.60,
13.8—18.8}
3 13.8—18.8}
B
E
C C
8
F
5
4 18.6—25.5
{1.90—2.60, G
13.8—18.8} 9
E
6
98—120
2 {10—12, 73—88}
A
B 78.4—101.9 {8.0—10.3, 57.9—75.1} 18.6—25.5 {1.90—2.60, 13.8—18.8}
18.6—25.5
{1.90—2.60,
13.8—18.8}
22 H
G 23
D 24
F 20 10
7
21
H
D 3—6 N·m
3—6 N·m {40—60 kgf·cm,
7.8—10.8 N·m {40—60 kgf·cm, 30—50 in·lbf} 15
{80—110 kgf·cm, 30—50 in·lbf}
70—95 in·lbf} 16
20 13
19
18
17
11
14
9.8—14.7 N·m
{100—149 kgf·cm, 12
87—130 in·lbf} N·m {kgf·m, ft·lbf}
acxuuw00001868
04-12–4
1871-1U-06B(04-12).fm 5 ページ 2006年3月15日 水曜日 午前11時15分
2 END CABLE
TAB
1
REAR PARKING BRAKE CABLE
acxuuw00001869
acxuuw00001050
04-12–5
1871-1U-06B(04-12).fm 6 ページ 2006年3月15日 水曜日 午前11時15分
Note
• When removing the parking brake shoe,
firmly press the adjuster bolt and tappet by
hand and slowly remove the parking brake
shoe to prevent the adjuster bolt, tappet,
operation lever and other parts from flying
off.
acxuuw00001757
Operation lever, Pin, Adjuster Bolt and Nut, Tappet Installation Note
1. Install the operation lever, pin, adjuster bolt and
OPERATION LEVER
nut, and tappet so that the adjuster nut is facing
toward the vehicle front.
2. Completely tighten the adjuster bolt and nut. ADJUSTER BOLT
3. Move the operation lever by hand and verify that it
operates properly.
TAPPET
• If proper operation cannot be verified,
reinstall.
FRONT
acxuuw00001053
SHOE STOPPER
04-12–6
1871-1U-06B(04-12).fm 7 ページ 2006年3月15日 水曜日 午前11時15分
acxuuw00001056
(2) Return the adjuster 13—17 notches in the
direction of the arrow.
Note
• Shoe clearance can be adjusted to 0.15 mm
{0.006 in} by returning the adjuster 15
notches.
TAB
REAR PARKING BRAKE CABLE
acxuuw00001870
04-12–7
1871-1U-06B(04-12).fm 8 ページ 2006年3月15日 水曜日 午前11時15分
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. Perform the following procedure and remove the parking brake pedal.
(1) Remove the lower panel. (See 09-17-9 LOWER PANEL REMOVAL/INSTALLATION.)
2. Perform the following procedure and remove the front parking brake cable.
(1) Remove the lower panel. (See 09-17-9 LOWER PANEL REMOVAL/INSTALLATION.)
(2) Remove the joint cover. (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(3) Remove the console panel. (See 09-17-15 CONSOLE PANEL REMOVAL/INSTALLATION.)
(4) Remove the console. (See 09-17-13 CONSOLE REMOVAL/INSTALLATION.)
(5) Remove the console bracket as shown in the
figure.
(6) Turn the floor covering over until the front
parking brake cable cover appears.
CONSOLE BRACKET
acxuuw00001871
(7) Disconnect the combined sensor connector
and the SAS control module connector. 8.8—12.8 N·m
{90—130 kgf·cm,
(8) Remove the sensor bracket component as 78—113 in·lbf}
shown in the figure.
(9) Remove the insulator.
3. Perform the following procedure and remove the
rear parking brake cable.
(1) Remove the insulator.
4. Perform the following procedure and remove the
parking brake plate, back plate and wheel hub.
(1) Remove the rear ABS wheel-speed sensor
from the trailing link. (See 04-15-13 REAR
ABS WHEEL-SPEED SENSOR REMOVAL/
INSTALLATION[AWD].)
(2) Remove the middle pipe. (See 01-15-2
EXHAUST SYSTEM REMOVAL/
INSTALLATION[L3 WITH TC].)
(3) Remove the rear stabilizer. (See 02-14-11 acxuuw00001872
REAR STABILIZER REMOVAL/
INSTALLATION.)
(4) Remove the rear coil spring. (See 02-14-6 REAR COIL SPRING REMOVAL/INSTALLATION.)
(5) Remove the trailing link component. (See 02-14-15 TRAILING LINK REMOVAL/INSTALLATION[AWD].)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Adjust the parking brake stroke. (See 04-12-2 PARKING BRAKE ADJUSTMENT.)
04-12–8
1871-1U-06B(04-12).fm 9 ページ 2006年3月15日 水曜日 午前11時15分
1 18.6—25.5
18.6—25.5
A {1.90—2.60,
{1.90—2.60,
13.8—18.8}
3 13.8—18.8}
B
E
C C
8
F
5
4 18.6—25.5
{1.90—2.60, G
13.8—18.8} 9
E
6 04-12
98—120
2 {10—12, 73—88}
A
B 78.4—101.9 {8.0—10.3, 57.9—75.1} 18.6—25.5 {1.90—2.60, 13.8—18.8}
18.6—25.5
{1.90—2.60,
13.8—18.8}
22 H
G 23
D 24
F 20 10
7
21
H
D 3—6 N·m
3—6 N·m {40—60 kgf·cm,
7.8—10.8 N·m {40—60 kgf·cm, 30—50 in·lbf} 15
{80—110 kgf·cm, 30—50 in·lbf}
70—95 in·lbf} 16
20 13
19
18
17
11
14
9.8—14.7 N·m
{100—149 kgf·cm, 12
87—130 in·lbf} N·m {kgf·m, ft·lbf}
acxuuw00001873
04-12–9
1871-1U-06B(04-12).fm 10 ページ 2006年3月15日 水曜日 午前11時15分
2 END CABLE
TAB
1
REAR PARKING BRAKE CABLE
acxuuw00001902
acxuuw00001050
04-12–10
1871-1U-06B(04-12).fm 11 ページ 2006年3月15日 水曜日 午前11時15分
Note
• When removing the parking brake shoe,
firmly press the adjuster bolt and tappet by
hand and slowly remove the parking brake
shoe to prevent the adjuster bolt, tappet,
operation lever and other parts from flying
off.
acxuuw00001051
Operation lever, Pin, Adjuster Bolt and Nut, Tappet Installation Note 04-12
1. Install the operation lever, pin, adjuster bolt and
OPERATION LEVER
nut, and tappet so that the adjuster nut is facing
toward the vehicle front.
2. Completely tighten the adjuster bolt and nut. ADJUSTER BOLT
3. Move the operation lever by hand and verify that it
operates properly.
TAPPET
• If proper operation cannot be verified,
reinstall.
FRONT
acxuuw00001053
SHOE STOPPER
04-12–11
1871-1U-06B(04-12).fm 12 ページ 2006年3月15日 水曜日 午前11時15分
acxuuw00001056
Note
• Shoe clearance can be adjusted to 0.15 mm
{0.006 in} by returning the adjuster 15
notches.
04-12–12
1871-1U-06B(04-12).fm 13 ページ 2006年3月15日 水曜日 午前11時15分
END CABLE
04-12
TAB
REAR PARKING BRAKE CABLE
acxuuw00001903
: Continuity
Terminal
Condition Body
A
ground
Parking brake pedal depressed
ampjjw00002631
acxuuw00001059
End Of Sie
04-12–13
1871-1U-06B(04-15).fm 1 ページ 2006年3月15日 水曜日 午前11時16分
End of Toc
WM: DYNAMIC STABILITY CONTROL
04-15–1
1871-1U-06B(04-15).fm 2 ページ 2006年3月15日 水曜日 午前11時16分
2WD
3
6 4
2
5 1 AWD
acxuuw00001778
End Of Sie
04-15–2
1871-1U-06B(04-15).fm 3 ページ 2006年3月15日 水曜日 午前11時16分
ABS 2 20A
C IG 1
E
ABS 1 40A Y F
B AB C COMBINED
AE A SENSOR
AA B
AI D
A
DSC 7.5A
J
IG SW 04-15
BATTERY STEERING
BCM ANGLE
SENSOR
BRAKE SYSTEM ABS WARNING
WARNING LIGHT LIGHT
CAN_L
CAN_H
DSC HU/CM
DSC INDICATOR
LIGHT
CAN
DRIVER
CAN_H
INSTRUMENT CLUSTER X CAN
PCM W DRIVER
CAN_L
CAN BRAKE SWITCH
DRIVER N
TCM
CAN
DRIVER
TSC OFF SWITCH
P
DLC-2
CAN_L
CAN_H
RF M
O
LF F
E
ABS WHEEL-
SPEED SENSOR
RR I
L
LR G
H D
acxuuw00002206
End Of Sie
04-15–3
1871-1U-06B(04-15).fm 4 ページ 2006年3月15日 水曜日 午前11時16分
DLC-2
acxuuw00001209
04-15–4
1871-1U-06B(04-15).fm 5 ページ 2006年3月15日 水曜日 午前11時16分
Caution
• To protect the DSC HU/CM, the solenoid valve and the pump motor used during active command
mode stay on for only 10 s or less each time they are switched on.
Note
• When working with two people, one should press on the brake pedal, and the other should attempt to
rotate the wheel being inspected.
4. Send the command while depressing on the brake pedal and attempting to rotate the wheel being inspected.
5. While brake pressure is maintained and a DSC HU/CM operation click sound is heard, confirm that the wheel
does not rotate. While brake pressure is being reduced and an DSC HU/CM operation click sound is heard,
confirm that the wheel rotates.
• Performing the inspection above determines the following:
— The DSC HU/CM brake lines are normal.
— The DSC HU/CM hydraulic system is not significantly abnormal (including DSC HU/CM).
— The DSC HU/CM internal electrical parts (solenoid, motor and other parts) are normal.
— The DSC unit and DSC HU/CM output system wiring harnesses (solenoid valve, relay system) are
normal.
• However, the following items cannot be verified.
— Malfunction with intermittent occurrence of the above items
— Malfunction of DSC HU/CM input system wiring harnesses and parts
— Extremely small leaks in the DSC HU/CM internal hydraulic system
04-15–5
1871-1U-06B(04-15).fm 6 ページ 2006年3月15日 水曜日 午前11時16分
Caution
• To protect the DSC HU/CM, the solenoid
valve and the pump motor used during
active command mode stay on for only 10
s or less each time they are switched on.
DLC-2
acxuuw00001209
Inspected wheels
Command name Understeer control inhibited Oversteer control inhibited
LF RF LR RR
V_TRC_L ON OFF ON
V_TRC_R OFF ON OFF
V_STB_L
OFF
V_STB_R
LF_INLET ON
OFF
LF_OUTLET
OFF
LR_INLET ON
OFF
LR_OUTLET
RF_INLET ON OFF
RF_OUTLET OFF
RR_INLET ON OFF
RR_OUTLET OFF
PMP_MOTOR ON
4. Send the command while rotating the wheel being inspected by hand in a forward direction.
5. Confirm that the wheel does not rotate easily while a DSC HU/CM operation click sound is heard.
• Performing the inspection above determines the following:
— The DSC HU/CM brake lines are normal.
— The DSC HU/CM hydraulic system is not significantly abnormal (including DSC HU/CM).
— The DSC HU/CM internal electrical parts (solenoid, motor and other parts) are normal.
— The DSC unit and DSC HU/CM output system wiring harnesses (solenoid valve, relay system) are
normal.
• However, the following items cannot be verified.
— Malfunction with intermittent occurrence of the above items
— Malfunction of DSC HU/CM input system wiring harnesses and parts
— Extremely small leaks in the DSC HU/CM internal hydraulic system
End Of Sie
DSC HU/CM REMOVAL/INSTALLATION
id041500801000
Caution
• The DSC may not function normally when the DSC HU/CM is replaced. After installation, always
perform the initialization procedures for the DSC HU/CM, combined sensor and the steering angle
sensor. (See 04-15-17 COMBINED SENSOR INITIALIZATION PROCEDURE.) (See 09-40-8
STEERING ANGLE SENSOR INITIALIZATION PROCEDURE.)
• The internal parts of the DSC HU/CM could be damaged if dropped. Be careful not to drop the DSC
HU/CM. Replace the DSC HU/CM if it is subjected to an impact.
1. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC].)
04-15–6
1871-1U-06B(04-15).fm 7 ページ 2006年3月15日 水曜日 午前11時16分
12.8—21.6
{131—220,
114—191}
1 E* 12.8—21.6
{131—220, 114—191}
3 SST *
C A
D B
4
7.8—10.8
{80—110, 70—95}
C
SST * 49 0259 770B 5
D
E * COMMERCIALLY AVAILABLE FLARE NUT WRENCH
(FLARE NUT ACROSS FLAT 10 mm {0.39 in}) N·m {kgf·cm, in·lbf}
acxuuw00001878
04-15–7
1871-1U-06B(04-15).fm 8 ページ 2006年3月15日 水曜日 午前11時16分
acxuuw00001149
MARK
acxuuw00001879
A
B
acxuuw00001880
RF
MASTER CYLINDER
(PRIMARY SIDE)
acxuuw00001210
04-15–8
1871-1U-06B(04-15).fm 9 ページ 2006年3月15日 水曜日 午前11時16分
LOCK LEVER
acxuuw00001152
AS AQ AO AM AK AI AG AE AC AA Y W U S Q O M K I G E
D C B A
AT AR AP AN AL AJ AH AF AD AB Z X V T R P N L J H F
acxuuw00001211
04-15–9
1871-1U-06B(04-15).fm 10 ページ 2006年3月15日 水曜日 午前11時16分
04-15–10
1871-1U-06B(04-15).fm 11 ページ 2006年3月15日 水曜日 午前11時16分
id041500800300
1. Perform the following procedure and remove the LF ABS wheel-speed sensor.
(1) Remove the battery and battery tray.
(2) Remove the air cleaner component and air hose. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/
INSTALLATION[L3 WITH TC].)
2. Remove in the order indicated in the table.
1 Front ABS wheel-speed sensor connector
2 Bolt
3 Front ABS wheel-speed sensor 1
2
7.8—10.8 N·m
{80—110 kgf·cm,
70—95 in·lbf}
acxuuw00001205
04-15–11
1871-1U-06B(04-15).fm 12 ページ 2006年3月15日 水曜日 午前11時16分
Clearance Inspection
1. Verify the clearance between the ABS sensor rotor and the ABS wheel-speed sensor.
• If there is any malfunction, check for improper installation, and replace if necessary.
FRONT ABS WHEEL-
Clearance SPEED SENSOR
• 0.7— 1.5 mm {0.028— 0.059 in}
CLEARANCE
FRONT ABS
SENSOR ROTOR
acxuuw00001206
04-15–12
1871-1U-06B(04-15).fm 13 ページ 2006年3月15日 水曜日 午前11時16分
7.8—10.8
2 {80—1110,
70—95}
N·m {kgf·cm,in·lbf}
acxuuw00001876
acxuuw00001877
04-15–13
1871-1U-06B(04-15).fm 14 ページ 2006年3月15日 水曜日 午前11時16分
Clearance Inspection
1. Remove the rear ABS wheel-speed sensor.
2. Measure the distance between the rear ABS
A
wheel-speed sensor installation surface and the CLEARANCE
ABS sensor rotor. This is dimension A. REAR ABS WHEEL-
3. Calculate the clearance between the front ABS SPEED SENSOR
wheel-speed sensor and the ABS sensor rotor
using the following formula:
REAR ABS
Clearance (mm {in}) = A-15.0 SENSOR ROTOR
15.0 mm {0.60 in}
4. Verify that the clearance between the ABS sensor
rotor and the rear ABS wheel-speed sensor is as
indicated below.
• If there is any malfunction, replace it.
acxuuw00001203
Clearance
• 0.3— 1.1 mm {0.012— 0.043 in}
Clearance Inspection
1. Verify the clearance between the ABS sensor rotor and the ABS wheel-speed sensor.
• If there is any malfunction, check for improper installation, and replace if necessary.
Clearance
• 0.3— 1.1 mm {0.012— 0.043 in}
REAR ABS WHEEL-
SPEED SENSOR
CLEARANCE
acxuuw00001372
04-15–14
1871-1U-06B(04-15).fm 15 ページ 2006年3月15日 水曜日 午前11時16分
Caution
• The internal parts of the combined sensor could be damaged if dropped. Be careful not to drop the
combined sensor. Replace the combined sensor if it is subjected to an impact. Also, do not use an
impact wrench or other similar air tools when removing/installing the sensor.
1
acxuuw00001881
04-15–15
1871-1U-06B(04-15).fm 16 ページ 2006年3月15日 水曜日 午前11時16分
DLC-2
acxuuw00001213
Standard
When the sensor is tilted to the right (A):
LAT_ACCL changes negatively. B
When the sensor is tilted to the left (B):
LAT_ACCL changes positively. VEHICLE FRONT
acxuuw00001214
(2) Yaw rate inspection
1) Verify the YAW_RATE change when the
combined sensor is rotated to the left and
B
right.
• If there is any malfunction, replace the
combined sensor.
Standard A
When the sensor is rotated to the right (A):
YAW_RATE changes negatively.
When the sensor is rotated to the left (B):
YAW_RATE changes positively.
VEHICLE FRONT
acxuuw00001215
End Of Sie
04-15–16
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
DYNAMIC STABILITY CONTROL
COMBINED SENSOR INITIALIZATION PROCEDURE
id041500801400
Warning
• Unless the initialization procedure of the combined sensor is completed, the DSC will not operate,
causing an unexpected accident. Therefore, always perform the initialization procedure to ensure
DSC operation if the combined sensor and DSC HU/CM have been removed or replaced.
id041500801500
1. Turn the ignition switch off.
2. Install the SSTs to the master cylinder.
49 U043 004A 49 U043 006
Note
• Install the SST (49 N043 001) to the master
cylinder using a commercially available flare
nut wrench. A
— Flare nut across flat: 12 mm {0.47 in}
3. Bleed the air from the SSTs and the brake line.
(Bleed air from the SSTs) through air bleeding
valve A. 49 N043 001
49 U043 005
acxuuw00001882
acxuuw00001779
: Bulb : Continuity F E D C B A
Terminal
Condition
A C E F
E C
Switch pressed
Switch released
acxuuw00001221
acxuuw00001220
End Of Sie
04-15–18
1871-1U-06B(04-50).fm 1 ページ 2006年3月15日 水曜日 午前11時16分
TECHNICAL DATA
04-50 TECHNICAL DATA
BRAKES TECHNICAL DATA . . . . . . . . . 04-50–1
End of Toc
BRAKES TECHNICAL DATA
WM: BRAKES
id045000800100
Item Specification
Brake fluid type SAE J1703, FMVSS 116 DOT-3
Brake pedal height (reference value) 204.3 mm {8.043 in}
Brake pedal play 2—5 mm {0.08—0.19 in}
Brake pedal-to-floor clearance (Brake pedal when
99.1 mm {3.91 in} or more
depressed at 147 N {15.0 kgf, 33.0 lbf})
Front disc plate runout limit 0.05 mm {0.002 in} 04-50
Minimum front disc plate thickness 26 mm {1.03 in}
Minimum front disc plate thickness after machining
26.8 mm {1.06 in}
using a brake lathe on-vehicle
Minimum front disc pad thickness 2.0 mm {0.08 in}
Rear disc plate runout limit 0.05 mm {0.002 in}
Minimum rear disc plate thickness 16 mm {0.63 in}
Minimum rear disc plate thickness after machining
16.8 mm {0.66 in}
using a brake lathe on-vehicle
Minimum rear disc pad thickness 2.0 mm {0.08 in}
Parking brake pedal stroke when depressed at 180 N
1—3 notches
{18.4 kgf, 40.5 lbf}
Minimum parking brake shoe thickness 1.0 mm {0.04 in}
Maximum rear disc plate inner diameter 191.0 mm {7.52 in}
End Of Sie
04-50–1
1871-1U-06B(04-60).fm 1 ページ 2006年3月15日 水曜日 午前11時17分
SERVICE TOOLS
04-60 SERVICE TOOLS
BRAKES SST . . . . . . . . . . . . . . . . . . . . . 04-60–1
End of Toc
BRAKES SST
WM: BRAKES
id046000800100
04-60
49 U043 006 49 U043 005 49 N043 001
49 T033 001A
Disc brake
piston stopper — —
End Of Sie
04-60–1
1871-1U-06B(05-02).fm 1 ページ 2006年3月15日 水曜日 午前11時18分
TRANSMISSION/TRANSAXLE 05
SECTION
Toc of SCT
ON-BOARD DIAGNOSTIC AUTOMATIC TRANSAXLE
[AW6A-EL, AW6AX-EL] . . . . . 05-02 [AW6A-EL, AW6AX-EL] . . . . 05-17
SYMPTOM AUTOMATIC TRANSAXLE
TROUBLESHOOTING SHIFT MECHANISM . . . . . . . 05-18
[AW6A-EL, AW6AX-EL] . . . . . 05-03 TECHNICAL DATA . . . . . . . . . . 05-50
SERVICE TOOLS . . . . . . . . . . . 05-60
Toc of SCT 05-02
05-02 ON-BOARD DIAGNOSTIC [AW6A-EL, AW6AX-EL]
AUTOMATIC TRANSAXLE CONTROL SYSTEM DTC P0819[AW6A-EL, AW6AX-EL] . . . . 05-02–38
WIRING DIAGRAM DTC P0882[AW6A-EL, AW6AX-EL] . . . . 05-02–40
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-02–2 DTC P0883[AW6A-EL, AW6AX-EL] . . . . 05-02–42
FOREWORD[AW6A-EL, AW6AX-EL] . . . 05-02–3 DTC P0942[AW6A-EL, AW6AX-EL] . . . . 05-02–42
AUTOMATIC TRANSAXLE ON-BOARD DTC P0961[AW6A-EL, AW6AX-EL] . . . . 05-02–44
DIAGNOSTIC FUNCTION DTC P0962[AW6A-EL, AW6AX-EL] . . . . 05-02–45
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-02–3 DTC P0963[AW6A-EL, AW6AX-EL] . . . . 05-02–47
DTC Reading Procedure. . . . . . . . . . . . 05-02–3 DTC P0973[AW6A-EL, AW6AX-EL] . . . . 05-02–49
AFTER REPAIR PROCEDURE DTC P0974[AW6A-EL, AW6AX-EL] . . . . 05-02–51
[AW6A-EL, AW6AX-EL] . . . . . . . . . . . . . 05-02–4 DTC P0976[AW6A-EL, AW6AX-EL] . . . . 05-02–53
DTC TABLE[AW6A-EL, AW6AX-EL] . . . . 05-02–5 DTC P0977[AW6A-EL, AW6AX-EL] . . . . 05-02–55
DTC P0601[AW6A-EL, AW6AX-EL] . . . . 05-02–10 DTC P0978[AW6A-EL, AW6AX-EL] . . . . 05-02–57
DTC P0603[AW6A-EL, AW6AX-EL] . . . . 05-02–10 DTC P0979[AW6A-EL, AW6AX-EL] . . . . 05-02–59
DTC P0604[AW6A-EL, AW6AX-EL] . . . . 05-02–11 DTC P0980[AW6A-EL, AW6AX-EL] . . . . 05-02–61
DTC P0706[AW6A-EL, AW6AX-EL] . . . . 05-02–12 DTC P0981[AW6A-EL, AW6AX-EL] . . . . 05-02–63
DTC P0707[AW6A-EL, AW6AX-EL] . . . . 05-02–12 DTC P0982[AW6A-EL, AW6AX-EL] . . . . 05-02–64
DTC P0708[AW6A-EL, AW6AX-EL] . . . . 05-02–13 DTC P0983[AW6A-EL, AW6AX-EL] . . . . 05-02–66
DTC P0711[AW6A-EL, AW6AX-EL] . . . . 05-02–14 DTC P0984[AW6A-EL, AW6AX-EL] . . . . 05-02–68
DTC P0712[AW6A-EL, AW6AX-EL] . . . . 05-02–15 DTC P0985[AW6A-EL, AW6AX-EL] . . . . 05-02–69
DTC P0713[AW6A-EL, AW6AX-EL] . . . . 05-02–17 DTC P0986[AW6A-EL, AW6AX-EL] . . . . 05-02–71
DTC P0717[AW6A-EL, AW6AX-EL] . . . . 05-02–18 DTC P0997[AW6A-EL, AW6AX-EL] . . . . 05-02–73
DTC P0722[AW6A-EL, AW6AX-EL] . . . . 05-02–20 DTC P0998[AW6A-EL, AW6AX-EL] . . . . 05-02–74
DTC P0729[AW6A-EL, AW6AX-EL] . . . . 05-02–22 DTC P0999[AW6A-EL, AW6AX-EL] . . . . 05-02–76
DTC P0730[AW6A-EL, AW6AX-EL] . . . . 05-02–24 DTC P1700[AW6A-EL, AW6AX-EL] . . . . 05-02–78
DTC P0731[AW6A-EL, AW6AX-EL] . . . . 05-02–26 DTC P2757[AW6A-EL, AW6AX-EL] . . . . 05-02–79
DTC P0732[AW6A-EL, AW6AX-EL] . . . . 05-02–27 DTC P2758[AW6A-EL, AW6AX-EL] . . . . 05-02–80
DTC P0733[AW6A-EL, AW6AX-EL] . . . . 05-02–29 DTC P2762[AW6A-EL, AW6AX-EL] . . . . 05-02–82
DTC P0734[AW6A-EL, AW6AX-EL] . . . . 05-02–30 DTC P2763[AW6A-EL, AW6AX-EL] . . . . 05-02–83
DTC P0735[AW6A-EL, AW6AX-EL] . . . . 05-02–32 DTC P2764[AW6A-EL, AW6AX-EL] . . . . 05-02–85
DTC P0736[AW6A-EL, AW6AX-EL] . . . . 05-02–33 PID/DATA MONITOR INSPECTION
DTC P0780[AW6A-EL, AW6AX-EL] . . . . 05-02–35 [AW6A-EL, AW6AX-EL] . . . . . . . . . . . . 05-02–87
DTC P0817[AW6A-EL, AW6AX-EL] . . . . 05-02–36 Simulation Function Procedure . . . . . . 05-02–89
End of Toc
WM: AUTOMATIC TRANSAXLE
05-02–1
1871-1U-06B(05-02).fm 2 ページ 2006年3月15日 水曜日 午前11時18分
SHIFT SOLENOID A
TR SWITCH
(INTEGRATED IN TCM) B5
SHIFT SOLENOID B
B2
B13
LINE PRESSURE
CONTROL SOLENOID
B8 B3
TFT SENSOR B1
B7
SHIFT SOLENOID F
UP SWITCH B21
A3
B16
DOWN SWITCH
A4
M RANGE SWITCH
A7
TCM SHIFT SOLENOID C
B11
OTHER MODULE
CAN-H B10
A14
CAN
CAN-L
A6 SHIFT SOLENOID D
B17
OTHER MODULE
B18
SHIFT SOLENOID E
B14
B22
IG1
A11
B+ STARTER RELAY
A5
A1
D6U517CS7004
End Of Sie
05-02–2
1871-1U-06B(05-02).fm 3 ページ 2006年3月15日 水曜日 午前11時18分
CUSTOMER ARRIVES
05-02
WARNING LIGHT* NO WARNING LIGHT*
ON/FLASHING WITH SYMPTOM
WITHOUT DTC
DIAGNOSE BY DTC
(ON-BOARD DIAGNOSTIC) DIAGNOSE BY SYMPTOM
DTC TABLE (SYMPTOM TROUBLESHOOTING)
DTC 1. DIAGNOSTIC INDEX
TROUBLESHOOTING 2. QUICK DIAGNOSIS CHART
FLOW 3. SYMPTOM
TROUBLESHOOTING
C6U0502W003
05-02–3
1871-1U-06B(05-02).fm 4 ページ 2006年3月15日 水曜日 午前11時18分
Caution
• After repairing a malfunction, perform this procedure to verify that the malfunction has been
corrected.
• When this procedure is carried out, be sure to drive the vehicle at lawful speed and pay attention
to the other vehicles.
05-02–4
1871-1U-06B(05-02).fm 5 ページ 2006年3月15日 水曜日 午前11時18分
X: Available
AT
Monitor Memory
DTC No. Condition MIL warning DC Page
item function
light
(See 05-02-10
DTC
P0601 Flash ROM malfunction X X 1 CCM X P0601[AW6A-
EL, AW6AX-
EL])
(See 05-02-10
DTC
P0603 EEPROM malfunction X X 1 – X P0603[AW6A-
EL, AW6AX-
EL])
(See 05-02-11
DTC
P0604 RAM malfunction X X 1 CCM X P0604[AW6A-
EL, AW6AX-
EL])
(See 05-02-12
DTC
Transaxle range (TR) switch circuit range/
P0706 X X 1 Other X P0706[AW6A-
performance
EL, AW6AX-
EL])
(See 05-02-12
DTC
P0707 Transaxle range (TR) switch circuit low input X X 1 CCM X P0707[AW6A-
EL, AW6AX-
EL])
(See 05-02-13
DTC
P0708 Transaxle range (TR) switch circuit high input X X 1 CCM X P0708[AW6A-
EL, AW6AX-
EL])
05-02–5
1871-1U-06B(05-02).fm 6 ページ 2006年3月15日 水曜日 午前11時18分
05-02–6
1871-1U-06B(05-02).fm 7 ページ 2006年3月15日 水曜日 午前11時18分
05-02–7
1871-1U-06B(05-02).fm 8 ページ 2006年3月15日 水曜日 午前11時18分
05-02–8
1871-1U-06B(05-02).fm 9 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–9
1871-1U-06B(05-02).fm 10 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Replace the TCM, then go to the next step.
• Is any related repair information available? (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
AW6AX-EL].)
3 VERIFY TROUBLESHOOTING OF DTC P0601 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie
DTC P0603[AW6A-EL, AW6AX-EL]
id050211800700
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
05-02–10
1871-1U-06B(05-02).fm 11 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0604[AW6A-EL, AW6AX-EL]
id050211800800
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Replace the TCM, then go to the next step.
• Is any related repair information available? (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
AW6AX-EL].)
3 VERIFY TROUBLESHOOTING OF DTC P0604 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie
05-02–11
1871-1U-06B(05-02).fm 12 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Replace the TCM, then go to the next step.
• Is any related repair information available? (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
AW6AX-EL].)
3 VERIFY TROUBLESHOOTING OF DTC P0706 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in each range (P— D).
• Is same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie
DTC P0707[AW6A-EL, AW6AX-EL]
id050211801000
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
05-02–12
1871-1U-06B(05-02).fm 13 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0708[AW6A-EL, AW6AX-EL]
id050211801100
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Replace the TCM, then go to the next step.
• Is any related repair information available? (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
AW6AX-EL].)
3 VERIFY TROUBLESHOOTING OF DTC P0708 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in each range (P— D).
• Is same DTC present?
4 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie
05-02–13
1871-1U-06B(05-02).fm 14 ページ 2006年3月15日 水曜日 午前11時18分
TCM
COUPLE COMPONENT CONNECTOR
COUPLE COMPONENT
3
B8 (+)
TFT B7 B8
SENSOR 4
3
B7 (-)
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 5.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-25 TCM REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
05-02–14
1871-1U-06B(05-02).fm 15 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0712[AW6A-EL, AW6AX-EL]
id050211801300
DTC P0712 Transaxle fluid temperature (TFT) sensor circuit malfunction (short to ground)
• If the TCM detects the following condition for 10 s or more, the TCM determines that the TFT sensor circuit
has a malfunction.
— ATF temperature 200 °C {392 °F} or more
Diagnostic support note:
DETECTION • This is continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• TFT sensor malfunction
• Short to ground in wiring harness between TFT sensor and TCM terminal B8
POSSIBLE
• Short to ground in wiring harness between TFT sensor and TCM terminal B7
CAUSE
• Damaged connector TCM
• TCM malfunction
05-02–15
1871-1U-06B(05-02).fm 16 ページ 2006年3月15日 水曜日 午前11時18分
TCM
COUPLE COMPONENT CONNECTOR
COUPLE COMPONENT
3
B8 (+)
TFT B7 B8
SENSOR 4
3
B7 (-)
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 5.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-25 TCM REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
4 INSPECT RESISTANCE OF TFT SENSOR Yes Go to the next step.
CIRCUIT No Replace the TFT sensor, then go to the next step.
• Inspect for resistance between couple (See 05-17-13 TRANSAXLE FLUID TEMPERATURE
component terminals B8 and B7 (wiring (TFT) SENSOR REMOVAL/INSTALLATION[AW6A-EL,
harness-side). AW6AX-EL].)
• Is resistance as shown below?
— ATF temperature 10°C {50°F}: 5.62— 7.31
kilohms
— ATF temperature 25°C {77°F}: 3.5 kilohms
— ATF temperature 110°C {230°F}: 0.22—
0.27 kilohms
(See 05-17-12 TRANSAXLE FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION[AW6A-EL, AW6AX-EL].)
5 VERIFY TROUBLESHOOTING OF DTC P0712 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is same DTC present?
05-02–16
1871-1U-06B(05-02).fm 17 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0713[AW6A-EL, AW6AX-EL]
id050211801400
DTC P0713 Transaxle fluid temperature (TFT) sensor circuit malfunction (short to power/open circuit)
• If the TCM detects the following condition for 1 s or more, the TCM determines that the TFT sensor circuit
has a malfunction.
— Engine warmed-up
— ATF temperature less than –43 °C {–45.4 °F}
Diagnostic support note:
DETECTION
CONDITION • This is continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during first drive cycle.
• A PENDING CODE is not available. 05-02
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• TFT sensor malfunction
• Open circuit in wiring harness between TFT sensor and TCM terminal B8
• Open circuit in wiring harness between TFT sensor and TCM terminal B7
POSSIBLE
• Short to power in wiring harness between TFT sensor and TCM terminal B8
CAUSE
• Short to power in wiring harness between TFT sensor and TCM terminal B7
• Damaged connector TCM
• TCM malfunction
TCM
COUPLE COMPONENT CONNECTOR
COUPLE COMPONENT
3
B8 (+)
TFT B7 B8
SENSOR 4
3
B7 (-)
05-02–17
1871-1U-06B(05-02).fm 18 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0717[AW6A-EL, AW6AX-EL]
id050211801500
DTC P0717 Input/turbine speed sensor circuit malfunction (open circuit/short circuit)
• When all conditions below are satisfied.
— D range of TR switch input
— Driving vehicle at vehicle speed of 20 km/h {12 mph} or more
— Vehicle speed signal 24 pulse input
— Input/turbine speed sensor signal not input
• Normal turbine speed signal is not input.
DETECTION
Diagnostic support note:
CONDITION
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
05-02–18
1871-1U-06B(05-02).fm 19 ページ 2006年3月15日 水曜日 午前11時18分
TCM
COUPLE COMPONENT
3
6 7
B12 (+)
5
B
INPUT/TURBINE
05-02
4
SPEED SENSOR
A
5 3
6 7
B13 (-)
B A
B12 B13
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See05-17-25 TCM REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
05-02–19
1871-1U-06B(05-02).fm 20 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0722[AW6A-EL, AW6AX-EL]
id050211801600
DTC P0722 Vehicle speed sensor (VSS) circuit malfunction (open circuit/short circuit)
• When all conditions below are satisfied.
— D range of TR switch input
— Driving vehicle at vehicle speed of 20 km/h {12 mph} or more
— Turbine speed signal 16 pulse input
— VSS signal not input
• Normal vehicle speed signal is not input for 0.1 s or more.
DETECTION
Diagnostic support note:
CONDITION
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
05-02–20
1871-1U-06B(05-02).fm 21 ページ 2006年3月15日 水曜日 午前11時18分
TCM
COUPLE COMPONENT
3
6 7
B19 (+)
5
B
05-02
VSS 4
A
5 3
6 7
B20 (-)
B19 B20
B A
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-25 TCM REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
05-02–21
1871-1U-06B(05-02).fm 22 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0729[AW6A-EL, AW6AX-EL]
id050211801700
05-02–22
1871-1U-06B(05-02).fm 23 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded? 05-02
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the transaxle, then go to Step 8.
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
• Is it normal?
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 8.
• Warm up the ATX.
• Is the ATF level within the specification?
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 8.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM Step 8.
TEST[AW6A-EL, AW6AX-EL].) (See 05-17-38 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION[AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go to Step 8.
(See 05-17-3 MECHANICAL SYSTEM (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
TEST[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
7 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-20 SOLENOID VALVE (See 05-17-38 CONTROL VALVE BODY REMOVAL/
INSPECTION[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is it normal?
05-02–23
1871-1U-06B(05-02).fm 24 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0730[AW6A-EL, AW6AX-EL]
id050211801800
DTC P0730 Gear 1 and engine brake operation incorrect (incorrect gear ratio detected)
• Engine braking is detected to be not operating when following conditions are satisfied while driving:
Monitoring condition:
— ATF temperature 20 °C {68 °F} or more
— Driving in 1GR in M range
— Engine running
— Accelerator opening angle 10% or more
DETECTION — Vehicle speed signal normal
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL does not illuminate if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• ATF level low
• Deteriorated ATF
• Shift solenoid A stuck
• Shift solenoid B stuck
• Shift solenoid D stuck
• Shift solenoid E stuck
POSSIBLE • Shift solenoid F stuck
CAUSE • Line pressure control solenoid stuck
• Line pressure low
• C1 clutch slipping
• B2 brake slipping
• Control valve stuck
• Oil pump malfunction
• TCM malfunction
05-02–24
1871-1U-06B(05-02).fm 25 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–25
1871-1U-06B(05-02).fm 26 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the transaxle, then go to Step 8.
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
• Is it normal?
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 8.
• Warm up the ATX.
• Is the ATF level within the specification?
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 8.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM Step 8.
TEST[AW6A-EL, AW6AX-EL].) (See 05-17-38 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION[AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go to Step 8.
(See05-17-3 MECHANICAL SYSTEM (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
TEST[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
05-02–26
1871-1U-06B(05-02).fm 27 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0732[AW6A-EL, AW6AX-EL]
id050211802000
05-02–27
1871-1U-06B(05-02).fm 28 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–28
1871-1U-06B(05-02).fm 29 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the transaxle, then go to Step 8.
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
• Is it normal?
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 8.
• Warm up the ATX.
• Is the ATF level within the specification?
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 8.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM Step 8.
TEST[AW6A-EL, AW6AX-EL].) (See 05-17-38 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION[AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go to Step 8.
(See 05-17-3 MECHANICAL SYSTEM (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
TEST[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
05-02–29
1871-1U-06B(05-02).fm 30 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0734[AW6A-EL, AW6AX-EL]
id050211802200
05-02–30
1871-1U-06B(05-02).fm 31 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–31
1871-1U-06B(05-02).fm 32 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Inspect the ATF condition. No Replace the transaxle, then go to Step 8.
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
• Is it normal?
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 8.
• Warm up the ATX.
• Is the ATF level within the specification?
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 8.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM Step 8.
TEST[AW6A-EL, AW6AX-EL].) (See 05-17-38 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION[AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go to Step 8.
(See 05-17-3 MECHANICAL SYSTEM (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
TEST[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
05-02–32
1871-1U-06B(05-02).fm 33 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0736[AW6A-EL, AW6AX-EL]
id050211802400
05-02–33
1871-1U-06B(05-02).fm 34 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–34
1871-1U-06B(05-02).fm 35 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT SOLENOID VALVE Yes Go to the next step.
• Inspect the solenoid valve. No Replace the control valve body, then go to the next step.
(See 05-17-20 SOLENOID VALVE (See 05-17-38 CONTROL VALVE BODY REMOVAL/
INSPECTION[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is it normal?
4 VERIFY TROUBLESHOOTING OF DTC P0780 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is same DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie
05-02–35
1871-1U-06B(05-02).fm 36 ページ 2006年3月15日 水曜日 午前11時18分
DTC P0817 Starter relay No.2 circuit malfunction (open circuit/short circuit)
• Any of the following conditions are met when ignition switch is at ON position:
— 0 V detected at TCM terminal A5 when in D range or R position
— 12 V detected at TCM terminal A5 when in P or N position
Diagnostic support note:
DETECTION
CONDITION • The MIL does not illuminate if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Open circuit between starter relay No.2 terminal A and TCM terminal A5
• Short to ground in wiring harness between starter relay No.2 terminal A and TCM terminal A5
POSSIBLE • Short to power in wiring harness between starter relay No.2 terminal A and TCM terminal A5
CAUSE • Starter relay No.2 malfunction
• Damaged connector between starter relay No.2 and TCM
• TCM malfunction
STARTER RELAY IG1
TCM
6
7 7
C E
STARTER
RELAY NO.2 8
3
4
D A
7 7 5
9 10 11
A5
PCM
E A
C A5
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
05-02–36
1871-1U-06B(05-02).fm 37 ページ 2006年3月15日 水曜日 午前11時18分
05-02–37
1871-1U-06B(05-02).fm 38 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0819[AW6A-EL, AW6AX-EL]
id050211802700
DTC P0819 Manual switch/up switch/down switch circuit malfunction (open circuit/short circuit)
• Any of the following conditions are detected for 10 s or more when engine is running:
— 5 V detected at TCM terminals A7 when in any position except D or M range.
— 0 V detected at TCM terminal A7 when 5 V are input to TCM terminal A3 or A4.
Diagnostic support note:
DETECTION
CONDITION • The MIL does not illuminate if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• M range switch malfunction
• Up switch malfunction
• Down switch malfunction.
• Open circuit in wiring harness between selector lever component terminal A and TCM terminal A3
• Open circuit in wiring harness between selector lever component terminal B and TCM terminal A4
POSSIBLE • Open circuit in wiring harness between selector lever component terminal C and TCM terminal A7
CAUSE • Open circuit in wiring harness between selector lever component terminal D and ground
• Short to ground in wiring harness between selector lever component terminal A and TCM terminal A3
• Short to ground in wiring harness between selector lever component terminal B and TCM terminal A4
• Short to ground in wiring harness between selector lever component terminal C and TCM terminal A7
• Damaged connector between selector lever component and TCM
• TCM malfunction
7 TCM
SELECTOR LEVER
COMPONENT
UP
SWITCH 5 6 9 3 4
A A3
DOWN
SWITCH 5 6 9 3 4
B A4
M RANGE
5 SWITCH
5 6 9 3 4
D C A7
8
C A
A3 A4 A7
D B
05-02–38
1871-1U-06B(05-02).fm 39 ページ 2006年3月15日 水曜日 午前11時18分
05-02–39
1871-1U-06B(05-02).fm 40 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0882[AW6A-EL, AW6AX-EL]
id050211802800
TCM
TCM 10 A METER IG 15 A TCM WIRING HARNESS-
FUSE FUSE SIDE CONNECTOR
3 5 6 4 7
3
A11
A1
4 7 A11
5 6 A9
A1
7
8
A9
05-02–40
1871-1U-06B(05-02).fm 41 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–41
1871-1U-06B(05-02).fm 42 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 VERIFY DTC Yes Go to the applicable DTC inspection.
• Turn the ignition switch to the LOCK position, (See 01-02-13 DTC TABLE[L3 WITH TC].)
then to the ON position. No Go to the next step.
• Verify the DTC in the PCM memory.
• Are DTC P2504 output?
4 VERIFY TROUBLESHOOTING OF DTC P0883 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Start the engine and warm it up completely.
• Is same DTC present?
5 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie
DTC P0942[AW6A-EL, AW6AX-EL]
id050211803000
DTC P0942 Valve control solenoid circuit malfunction at D range (valve stuck)
• Difference of less than 150 rpm between engine and turbine speeds detected when following conditions
are satisfied while driving:
Monitoring condition:
— Engine running
— Driving in D range
— Counter drive gear (output) revolution speed500 rpm or more (VSS)
DETECTION
CONDITION Diagnostic support note:
• This is a continuous monitor (CCM).
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
05-02–42
1871-1U-06B(05-02).fm 43 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
05-02
3 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 6.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM Step 6.
TEST[AW6A-EL, AW6AX-EL].) (See 05-17-38 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION[AW6A-EL, AW6AX-EL].)
specifications?
4 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go the Step 6.
(See 05-17-3 MECHANICAL SYSTEM (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
TEST[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
5 INSPECT SOLENOID VALVE Yes Go to the next step.
• Inspect the solenoid valve. No Replace the control valve body, then go to the next step.
(See 05-17-20 SOLENOID VALVE (See 05-17-38 CONTROL VALVE BODY REMOVAL/
INSPECTION[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is it normal?
6 VERIFY TROUBLESHOOTING OF DTC P0942 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is same DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie
05-02–43
1871-1U-06B(05-02).fm 44 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is light red or reddish brown, replace ATF,
• Inspect the ATF condition. then go to Step 7.
— Clear red: Normal (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT[AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-10 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION[AW6A-EL, AW6AX-EL].)
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No • All ranges: Replace the oil pump or control valve body,
• Measure the line pressures. then go to the next step.
(See 05-17-3 MECHANICAL SYSTEM • Any ranges: Replace the ATX, then go the next step.
TEST[AW6A-EL, AW6AX-EL].) (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
• Are the line pressures within the INSTALLATION[AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT LINE PRESSURE CONTROL Yes Go to the next step.
SOLENOID No Replace the control valve body.
• Inspect the line pressure control solenoid. (See 05-17-38 CONTROL VALVE BODY REMOVAL/
(See 05-17-20 SOLENOID VALVE INSTALLATION[AW6A-EL, AW6AX-EL].)
INSPECTION[AW6A-EL, AW6AX-EL].)
• Is it normal?
05-02–44
1871-1U-06B(05-02).fm 45 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0962[AW6A-EL, AW6AX-EL]
id050211803200
05-02
DTC P0962 Line pressure control solenoid circuit malfunction (short to ground/open circuit)
• Open or short circuit in line pressure control solenoid signal system (The solenoid circuit current value input
to the TCM is continuously less than 23 mA for 100 ms or more).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Open circuit between line pressure control solenoid terminal B and TCM terminal B3
• Open circuit between line pressure control solenoid terminal A and TCM terminal B1
• Short to ground in wiring harness between line pressure control solenoid terminal B and TCM terminal B3
POSSIBLE
• Short to ground in wiring harness between line pressure control solenoid terminal A and TCM terminal B1
CAUSE
• Line pressure control solenoid malfunction
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction
05-02–45
1871-1U-06B(05-02).fm 46 ページ 2006年3月15日 水曜日 午前11時18分
TCM
COUPLE COMPONENT
3
6 7
B3 (+)
5
B
LINE PRESSURE 4
CONTROL SOLENOID
A
5 3
6 7
B1 (-)
B A
B1 B3
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-25 TCM REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
4 INSPECT RESISTANCE OF LINE PRESSURE Yes Go to go to Step 8.
CONTROL SOLENOID CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B3 and B1 (wiring
harness-side).
• Is resistance within 5.0— 5.6 ohms?
(See 05-17-20 SOLENOID VALVE
INSPECTION[AW6A-EL, AW6AX-EL].)
05-02–46
1871-1U-06B(05-02).fm 47 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0963[AW6A-EL, AW6AX-EL]
id050211803300
DTC P0963 Line pressure control solenoid circuit malfunction (short to power)
• Short circuit in line pressure control solenoid signal system (The solenoid circuit current value input to the
TCM is continuously more than 1,333 mA for 100 ms or more).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Short to power in wiring harness between line pressure control solenoid terminal B and TCM terminal B3
• Short to power in wiring harness between line pressure control solenoid terminal A and TCM terminal B1
POSSIBLE
• Line pressure control solenoid malfunction
CAUSE
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction
05-02–47
1871-1U-06B(05-02).fm 48 ページ 2006年3月15日 水曜日 午前11時18分
TCM
COUPLE COMPONENT
3
6
B3 (+)
5
B
LINE PRESSURE 4
CONTROL SOLENOID
A
5 3
6
B1 (-)
B A
B1 B3
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 7.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-25 TCM REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
4 INSPECT RESISTANCE OF LINE PRESSURE Yes Go to go to Step 7.
CONTROL SOLENOID CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminals B3 and B1 (wiring
harness-side).
• Is resistance within 5.0— 5.6 ohms?
(See 05-17-20 SOLENOID VALVE
INSPECTION[AW6A-EL, AW6AX-EL].)
05-02–48
1871-1U-06B(05-02).fm 49 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0973[AW6A-EL, AW6AX-EL]
id050211803400
05-02–49
1871-1U-06B(05-02).fm 50 ページ 2006年3月15日 水曜日 午前11時18分
COUPLE COMPONENT
3
6 7
B5
5
4 A
SHIFT SOLENOID A
A
B5
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 7.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-25 TCM REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID A Yes Go to go to Step 7.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminal B5 (wiring harness-side)
and ground.
• Is resistance within 11— 15 ohms?
(See 05-17-20 SOLENOID VALVE
INSPECTION[AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID A FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 7.
• Disconnect the shift solenoid A connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
05-02–50
1871-1U-06B(05-02).fm 51 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0974[AW6A-EL, AW6AX-EL]
id050211803500
05-02–51
1871-1U-06B(05-02).fm 52 ページ 2006年3月15日 水曜日 午前11時18分
COUPLE COMPONENT
3
6 7
B5
5
4 A
SHIFT SOLENOID A
A
B5
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-25 TCM REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID A Yes Go to go to Step 8.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminal B5 (wiring harness-side)
and ground.
• Is resistance within 11— 15 ohms?
(See 05-17-20 SOLENOID VALVE
INSPECTION[AW6A-EL, AW6AX-EL].)
5 INSPECT TERMINAL SHIFT SOLENOID A FOR Yes Go to the next step.
POOR CONNECTION No Replace the couple component, then go to Step 8.
• Disconnect the shift solenoid A connector.
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
05-02–52
1871-1U-06B(05-02).fm 53 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0976[AW6A-EL, AW6AX-EL]
id050211803600
05-02–53
1871-1U-06B(05-02).fm 54 ページ 2006年3月15日 水曜日 午前11時18分
TCM
COUPLE COMPONENT
3
6
B2
5
4 A
SHIFT SOLENOID B
B2
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 7.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-25 TCM REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID B Yes Go to go to Step 7.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminal B2 (wiring harness-side)
and ground.
• Is resistance within 11— 15 ohms?
(See 05-17-20 SOLENOID VALVE
INSPECTION[AW6A-EL, AW6AX-EL].)
05-02–54
1871-1U-06B(05-02).fm 55 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0977[AW6A-EL, AW6AX-EL]
id050211803700
05-02–55
1871-1U-06B(05-02).fm 56 ページ 2006年3月15日 水曜日 午前11時18分
TCM
COUPLE COMPONENT
3
6 7
B2
5
4 A
SHIFT SOLENOID B
B2
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT TERMINAL COUPLE COMPONENT Yes Go to the next step.
FOR POOR CONNECTION No Replace the couple component, then go to Step 8.
• Turn the ignition switch to the LOCK position.
• Remove the TCM.
(See 05-17-25 TCM REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
• Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
• Are terminals normal?
4 INSPECT RESISTANCE OF SHIFT SOLENOID B Yes Go to go to Step 8.
CIRCUIT No Go to the next step.
• Inspect for resistance between couple
component terminal B2 (wiring harness-side)
and ground.
• Is resistance within 11— 15 ohms?
(See 05-17-20 SOLENOID VALVE
INSPECTION[AW6A-EL, AW6AX-EL].)
05-02–56
1871-1U-06B(05-02).fm 57 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0978[AW6A-EL, AW6AX-EL]
id050211803800
05-02–57
1871-1U-06B(05-02).fm 58 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–58
1871-1U-06B(05-02).fm 59 ページ 2006年3月15日 水曜日 午前11時18分
COUPLE COMPONENT
3
6 7
B11 (+)
5
B
SHIFT SOLENOID C 4
A
5 3
6 7
B10 (-)
B A
B10 B11
05-02–59
1871-1U-06B(05-02).fm 60 ページ 2006年3月15日 水曜日 午前11時18分
05-02–60
1871-1U-06B(05-02).fm 61 ページ 2006年3月15日 水曜日 午前11時18分
TCM 05-02
COUPLE COMPONENT
3
6
B11 (+)
5
B
SHIFT SOLENOID C 4
A
5 3
6
B10 (-)
B A
B10 B11
05-02–61
1871-1U-06B(05-02).fm 62 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–62
1871-1U-06B(05-02).fm 63 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION 05-02
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is light red or reddish brown, replace ATF,
• Inspect the ATF condition. then go to Step 7.
— Clear red: Normal (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT[AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-10 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION[AW6A-EL, AW6AX-EL].)
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No • All ranges: Replace the oil pump or control valve body,
• Measure the line pressures. then go to the next step.
(See 05-17-3 MECHANICAL SYSTEM • Any ranges: Replace the ATX, then go the next step.
TEST[AW6A-EL, AW6AX-EL].) (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
• Are the line pressures within the INSTALLATION[AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-20 SOLENOID VALVE (See 05-17-38 CONTROL VALVE BODY REMOVAL/
INSPECTION[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is it normal?
7 VERIFY TROUBLESHOOTING OF DTC P0981 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is same DTC present?
05-02–63
1871-1U-06B(05-02).fm 64 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0982[AW6A-EL, AW6AX-EL]
id050211804200
TCM
COUPLE COMPONENT
6 7 3
B17 (+)
5
B
SHIFT SOLENOID D 4
A
5 6 7 3
B18 (-)
B A
B17 B18
05-02–64
1871-1U-06B(05-02).fm 65 ページ 2006年3月15日 水曜日 午前11時18分
05-02–65
1871-1U-06B(05-02).fm 66 ページ 2006年3月15日 水曜日 午前11時18分
TCM
COUPLE COMPONENT
3
6
B17 (+)
5
B
4
SHIFT SOLENOID D
A
5 3
6
B18 (-)
B A
B17 B18
05-02–66
1871-1U-06B(05-02).fm 67 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–67
1871-1U-06B(05-02).fm 68 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is light red or reddish brown, replace ATF,
• Inspect the ATF condition. then go to Step 7.
— Clear red: Normal (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT[AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-10 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION[AW6A-EL, AW6AX-EL].)
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No • All ranges: Replace the oil pump or control valve body,
• Measure the line pressures. then go to the next step.
(See 05-17-3 MECHANICAL SYSTEM • Any ranges: Replace the ATX, then go the next step.
TEST[AW6A-EL, AW6AX-EL].) (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
• Are the line pressures within the INSTALLATION[AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-20 SOLENOID VALVE (See05-17-38 CONTROL VALVE BODY REMOVAL/
INSPECTION[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is it normal?
7 VERIFY TROUBLESHOOTING OF DTC P0984 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is same DTC present?
05-02–68
1871-1U-06B(05-02).fm 69 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0985[AW6A-EL, AW6AX-EL]
id050211804500
TCM
COUPLE COMPONENT
6 7 3
B14 (+)
5
B
SHIFT SOLENOID E 4
A
5 6 7 3
B22 (-)
B22
B A
B14
05-02–69
1871-1U-06B(05-02).fm 70 ページ 2006年3月15日 水曜日 午前11時18分
05-02–70
1871-1U-06B(05-02).fm 71 ページ 2006年3月15日 水曜日 午前11時18分
TCM 05-02
COUPLE COMPONENT
3
6
B14 (+)
5
B
4
SHIFT SOLENOID E
A
5 3
6
B22 (-)
B22
B A
B14
05-02–71
1871-1U-06B(05-02).fm 72 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–72
1871-1U-06B(05-02).fm 73 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION 05-02
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is light red or reddish brown, replace ATF,
• Inspect the ATF condition. then go to Step 7.
— Clear red: Normal (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT[AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-10 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION[AW6A-EL, AW6AX-EL].)
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No • All ranges: Replace the oil pump or control valve body,
• Measure the line pressures. then go to the next step.
(See 05-17-3 MECHANICAL SYSTEM • Any ranges: Replace the ATX, then go the next step.
TEST[AW6A-EL, AW6AX-EL].) (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
• Are the line pressures within the INSTALLATION[AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT SHIFT SOLENOID Yes Go to the next step.
• Inspect the shift solenoid. No Replace the control valve body.
(See 05-17-20 SOLENOID VALVE (See05-17-38 CONTROL VALVE BODY REMOVAL/
INSPECTION[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is it normal?
7 VERIFY TROUBLESHOOTING OF DTC P0997 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is same DTC present?
05-02–73
1871-1U-06B(05-02).fm 74 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P0998[AW6A-EL, AW6AX-EL]
id050211804800
TCM
COUPLE COMPONENT
3
6 7
B21 (+)
5
B
4
SHIFT SOLENOID F
A
5 6 7 3
B16 (-)
B21
B A
B16
05-02–74
1871-1U-06B(05-02).fm 75 ページ 2006年3月15日 水曜日 午前11時18分
05-02–75
1871-1U-06B(05-02).fm 76 ページ 2006年3月15日 水曜日 午前11時18分
TCM
COUPLE COMPONENT
3
6
B21 (+)
5
B
SHIFT SOLENOID F 4
A
5 3
6
B16 (-)
B21
B A
B16
05-02–76
1871-1U-06B(05-02).fm 77 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–77
1871-1U-06B(05-02).fm 78 ページ 2006年3月15日 水曜日 午前11時18分
DTC P1700 Valve control solenoid circuit malfunction at R range (valve stuck)
• When all of the following conditions are met while driving in R position and the counter drive gear (output}
speed is 500 rpm or less:
— The difference between the engine and turbine shaft speeds is less than 150 rpm
— The turbine shaft speed is more than the estimated turbine speed value, as derived from the counter
drive gear (output) speed, plus 200 rpm.
DETECTION
Diagnostic support note:
CONDITION
• The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Shift solenoid A stuck
• Shift solenoid B stuck
• Shift solenoid E stuck
POSSIBLE
• C3 clutch slipping
CAUSE
• B2 brake slipping
• Control valve stuck
• TCM malfunction
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 6.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM Step 6.
TEST[AW6A-EL, AW6AX-EL].) (See 05-17-38 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION[AW6A-EL, AW6AX-EL].)
specifications?
4 INSPECT STALL SPEED Yes Go to the next step.
• Measure the stall speed in D range. No Replace the automatic transaxle, then go the Step 6.
(See 05-17-3 MECHANICAL SYSTEM (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
TEST[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is the stall speed within the specification?
5 INSPECT SOLENOID VALVE Yes Go to the next step.
• Inspect the solenoid valve. No Replace the control valve body, then go to the next step.
(See 05-17-20 SOLENOID VALVE (See 05-17-38 CONTROL VALVE BODY REMOVAL/
INSPECTION[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is it normal?
6 VERIFY TROUBLESHOOTING OF DTC P1700 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in R position.
• Is same DTC present?
7 VERIFY AFTER REPAIR PROCEDURE Yes Go to the applicable DTC inspection.
• Perform the “After Repair Procedure”. (See 05-02-5 DTC TABLE[AW6A-EL, AW6AX-EL].)
(See 05-02-4 AFTER REPAIR No DTC troubleshooting completed.
PROCEDURE[AW6A-EL, AW6AX-EL].)
• Are any DTCs present?
End Of Sie
05-02–78
1871-1U-06B(05-02).fm 79 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is milky or reddish brown, replace ATF, then
• Inspect the ATF condition. go to Step 7.
— Clear red: Normal (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT[AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-10 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION[AW6A-EL, AW6AX-EL].)
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No All ranges: Replace the oil pump, then go to Step 7.
• Measure the line pressures. Any ranges: Replace the control valve body, then go to
(See 05-17-3 MECHANICAL SYSTEM Step 6.
TEST[AW6A-EL, AW6AX-EL].) (See 05-17-38 CONTROL VALVE BODY REMOVAL/
• Are the line pressures within the INSTALLATION[AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT TCC CONTROL SOLENOID Yes Replace the Torque converter, then go to the next step.
• Inspect the TCC control solenoid. (See 05-17-46 TORQUE CONVERTER REMOVAL/
(See 05-17-20 SOLENOID VALVE INSTALLATION[AW6A-EL, AW6AX-EL].)
INSPECTION[AW6A-EL, AW6AX-EL].) No Replace the control valve body, then go to the next step.
• Is it normal? (See 05-17-38 CONTROL VALVE BODY REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
05-02–79
1871-1U-06B(05-02).fm 80 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P2758[AW6A-EL, AW6AX-EL]
id050211805200
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
05-02–80
1871-1U-06B(05-02).fm 81 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–81
1871-1U-06B(05-02).fm 82 ページ 2006年3月15日 水曜日 午前11時18分
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED No Record the FREEZE FRAME DATA on the repair order,
• Has the FREEZE FRAME DATA been then go to the next step.
recorded?
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to the available
AVAILABILITY repair information.
• Verify related Service Bulletins and/or on-line • If the vehicle is not repaired, go to the next step.
repair information availability. No Go to the next step.
• Is any related repair information available?
3 INSPECT ATF CONDITION Yes Go to the next step.
• Turn the ignition switch to the LOCK position. No If the ATF color is light red or reddish brown, replace ATF,
• Inspect the ATF condition. then go to Step 7.
— Clear red: Normal (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
— Light red (pink): Water mixed in fluid REPLACEMENT[AW6A-EL, AW6AX-EL].)
— Reddish brown: Deteriorated ATF
• Is it normal?
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
4 INSPECT ATF LEVEL Yes Go to the next step.
• Start the engine. No Add ATF to the specified level, then go to Step 7.
• Warm up the ATX. (See 05-17-10 AUTOMATIC TRANSAXLE FLUID (ATF)
• Is the ATF level within the specification? INSPECTION[AW6A-EL, AW6AX-EL].)
(See 05-17-10 AUTOMATIC TRANSAXLE
FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
5 INSPECT LINE PRESSURE Yes Go to the next step.
• Start the engine. No • All ranges: Replace the oil pump or control valve body,
• Measure the line pressures. then go to the next step.
(See 05-17-3 MECHANICAL SYSTEM • Any ranges: Replace the ATX, then go the next step.
TEST[AW6A-EL, AW6AX-EL].) (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
• Are the line pressures within the INSTALLATION[AW6A-EL, AW6AX-EL].)
specifications?
6 INSPECT TCC CONTROL SOLENOID Yes Go to the next step.
• Inspect the TCC control solenoid. No Replace the control valve body.
(See 05-17-20 SOLENOID VALVE (See 05-17-38 CONTROL VALVE BODY REMOVAL/
INSPECTION[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is it normal?
7 VERIFY TROUBLESHOOTING OF DTC P2762 Yes Replace the TCM, then go to the next step.
COMPLETED (See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
• Make sure to reconnect all the disconnected AW6AX-EL].)
connectors. No Go to the next step.
• Clear the DTC from the memory using the M-
MDS.
• Drive the vehicle in D range and make sure
that gears shift smoothly from 1GR to 6GR.
• Is same DTC present?
05-02–82
1871-1U-06B(05-02).fm 83 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
DTC P2763[AW6A-EL, AW6AX-EL]
id050211805400
TCM
COUPLE COMPONENT
3
6
B9 (+)
5
B
TCC CONTROL 4
SOLENOID
A
5 3
6
B4 (-)
B A
B9
B4
05-02–83
1871-1U-06B(05-02).fm 84 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–84
1871-1U-06B(05-02).fm 85 ページ 2006年3月15日 水曜日 午前11時18分
DTC P2764 TCC control solenoid circuit malfunction (short to ground/open circuit)
• Open or short circuit in TCC control solenoid signal system (while TCM monitors solenoid output voltage,
the voltage that differs from the signal output by CPU in TCM is detected).
Diagnostic support note:
DETECTION • This is a continuous monitor (CCM).
CONDITION • The MIL illuminates if the TCM detects the above malfunction condition during the first drive cycle.
• A PENDING CODE is not available.
• FREEZE FRAME DATA is available.
• The AT warning light illuminates.
• The DTC is stored in the TCM memory.
• Open circuit between TCC control solenoid terminal B and TCM terminal B9
• Open circuit between TCC control solenoid terminal A and TCM terminal B4
• Short to ground in wiring harness between TCC control solenoid terminal B and TCM terminal B9
POSSIBLE
• Short to ground in wiring harness between TCC control solenoid terminal A and TCM terminal B4
CAUSE
• TCC control solenoid malfunction
• Damaged connector between line pressure control solenoid and TCM
• TCM malfunction 05-02
TCM
COUPLE COMPONENT
6 7 3
B9 (+)
5
B
TCC CONTROL 4
SOLENOID
A
5 6 7 3
B4 (-)
B A
B9
B4
05-02–85
1871-1U-06B(05-02).fm 86 ページ 2006年3月15日 水曜日 午前11時18分
End Of Sie
05-02–86
1871-1U-06B(05-02).fm 87 ページ 2006年3月15日 水曜日 午前11時18分
Note 05-02
• Perform part inspection for the output device after TCM inspection.
• The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the TCM.
Therefore, if a monitored value of an output device is out of specification, it is necessary to inspect the
monitored value of the input device related to the output device control. Since an output device
malfunction is not directly indicated as a malfunction of the monitored value for the output device, it is
necessary to inspect the output device individually using the simulation function.
05-02–87
1871-1U-06B(05-02).fm 88 ページ 2006年3月15日 水曜日 午前11時18分
05-02–88
1871-1U-06B(05-02).fm 89 ページ 2006年3月15日 水曜日 午前11時18分
– : N/A
End Of Sie
05-02–89
1871-1U-06B(05-03).fm 1 ページ 2006年3月15日 水曜日 午前11時19分
End of Toc
WM: AUTOMATIC TRANSAXLE
05-03–1
1871-1U-06B(05-03).fm 2 ページ 2006年3月15日 水曜日 午前11時19分
SHIFT SOLENOID A
TR SWITCH
(INTEGRATED IN TCM) B5
SHIFT SOLENOID B
B2
B13
LINE PRESSURE
CONTROL SOLENOID
B8 B3
TFT SENSOR B1
B7
SHIFT SOLENOID F
UP SWITCH B21
A3
B16
DOWN SWITCH
A4
M RANGE SWITCH
A7
TCM SHIFT SOLENOID C
B11
OTHER MODULE
CAN-H B10
A14
CAN
CAN-L
A6 SHIFT SOLENOID D
B17
OTHER MODULE
B18
SHIFT SOLENOID E
B14
B22
IG1
A11
B+ STARTER RELAY
A5
A1
D6U517CS7004
End Of Sie
05-03–2
1871-1U-06B(05-03).fm 3 ページ 2006年3月15日 水曜日 午前11時19分
CUSTOMER ARRIVES
05-03
WARNING LIGHT* NO WARNING LIGHT*
ON/FLASHING WITH SYMPTOM
WITHOUT DTC
DIAGNOSE BY DTC
(ON-BOARD DIAGNOSTIC) DIAGNOSE BY SYMPTOM
DTC TABLE (SYMPTOM TROUBLESHOOTING)
DTC 1. DIAGNOSTIC INDEX
TROUBLESHOOTING 2. QUICK DIAGNOSIS CHART
FLOW 3. SYMPTOM
TROUBLESHOOTING
acxuuw00002535
05-03–3
1871-1U-06B(05-03).fm 4 ページ 2006年3月15日 水曜日 午前11時19分
End Of Sie
SYMPTOM TROUBLESHOOTING ITEM TABLE[AW6A-EL, AW6AX-EL]
id050310800400
• Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area.
No. TROUBLESHOOTING ITEM DESCRIPTION PAGE
1 • Vehicle does not move in D range, • Vehicle does not move when accelerator (See 05-03-11 NO.1 VEHICLE
or in R position pedal is depressed. DOES NOT MOVE IN D
RANGE, OR IN R
POSITION[AW6A-EL, AW6AX-
EL].)
2 • Vehicle moves in N position • Vehicle creeps in N position. (See 05-03-12 NO.2 VEHICLE
• Vehicle creeps if brake pedal is not MOVES IN N
depressed in N position. POSITION[AW6A-EL, AW6AX-
EL].)
3 • Vehicle moves in P position, or • Vehicle rolls when on a downward slope (See 05-03-12 NO.3 VEHICLE
parking gear does not disengage and tires do not lock in P position. MOVES IN P POSITION, OR
when P position is disengaged • Tires locked when P position is PARKING GEAR DOES NOT
disengaged, vehicle does not move in D DISENGAGE WHEN P IS
range, and R position when accelerator DISENGAGED[AW6A-EL,
pedal is depressed, and engine remains AW6AX-EL].)
in stalled condition.
4 • Excessive creep • Vehicle accelerates in D range, and R (See 05-03-12 NO.4
position when accelerator pedal is not EXCESSIVE CREEP[AW6A-
depressed. EL, AW6AX-EL].)
5 • No creep at all • Vehicle does not move in D range, or R (See 05-03-13 NO.5 NO
position when idling on flat paved road. CREEP AT ALL[AW6A-EL,
AW6AX-EL].)
6 • Low maximum speed and poor • Vehicle acceleration is poor at start. (See 05-03-14 NO.6 LOW
acceleration • Delayed acceleration when accelerator MAXIMUM SPEED AND
pedal is depressed while driving. POOR
ACCELERATION[AW6A-EL,
AW6AX-EL].)
7 • No shifting • Single shift range only. (See 05-03-15 NO.7 NO
• Sometimes shifts correctly. SHIFTING[AW6A-EL, AW6AX-
EL].)
8 • Does not shift to 6GR • Vehicle does not upshift from 5GR to (See 05-03-16 NO.8 DOES
6GR even though vehicle speed NOT SHIFT TO 6GR[AW6A-
increased. EL, AW6AX-EL].)
• Vehicle does not shift to 6GR even
though accelerator pedal is released in
D range at 80 km/h {50 mph}.
9 • Abnormal shifting • Shifts incorrectly (incorrect shift pattern). (See 05-03-17 NO.9
ABNORMAL
SHIFTING[AW6A-EL, AW6AX-
EL].)
05-03–4
1871-1U-06B(05-03).fm 5 ページ 2006年3月15日 水曜日 午前11時19分
05-03–5
1871-1U-06B(05-03).fm 6 ページ 2006年3月15日 水曜日 午前11時19分
End Of Sie
05-03–6
1871-1U-06B(05-03).fm 7 ページ 2006年3月15日 水曜日 午前11時19分
M range switch
Shift position (to instrument cluster)
Accelerator opening (from PCM)
TR switch
Up switch
Parking mechanism not operating properly
No signal input
No signal input
Open/short
Open/short
Open/short
Open/short
Cause of trouble
acxuuw00002272
05-03–7
1871-1U-06B(05-03).fm 8 ページ 2006年3月15日 水曜日 午前11時19分
Input/turbine
TFT sensor
VSS
Shift solenoid E
Shift solenoid D
Shift solenoid F
Shift solenoid C
Shift solenoid B
Shift solenoid A
Malfunction signal input
Abnormal signal input
No signal input
No signal input
Open/short
Open/short
Open/short
Open/short
Open/short
Open/short
Open/short
Open/short
Open/short
Open/short
Cause of trouble
acxuuw00002273
05-03–8
1871-1U-06B(05-03).fm 9 ページ 2006年3月15日 水曜日 午前11時19分
Cause of trouble
acxuuw00002274
05-03–9
1871-1U-06B(05-03).fm 10 ページ 2006年3月15日 水曜日 午前11時19分
Powertrain
Symptom item
Torque converter is not operating properly
One-way clutch is not operated properly
Cause of trouble
acxuuw00002275
End Of Sie
05-03–10
1871-1U-06B(05-03).fm 11 ページ 2006年3月15日 水曜日 午前11時19分
Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
Diagnostic procedure
STEP INSPECTION ACTION
1 • When the vehicle is stopped on a flat, level Yes Go to the next step.
road and the engine off, does the vehicle No Inspect for parking mechanism.
move when pushed? (in D range or N, R
positions with the brake pedal released)
2 • Start the engine. Yes Inspect or adjust selector lever.
• Does vehicle move when selector lever in (See 05-18-6 SELECTOR LEVER INSPECTION.)
between N position and D range? (See 05-18-7 SELECTOR CABLE ADJUSTMENT.)
Perform N position learning.
(See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
AW6AX-EL].)
No Go to the next step.
3 • Stop the engine. Yes Replace the ATX (clutch slippage, worn)
• Inspect following solenoid. (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
(See 05-17-20 SOLENOID VALVE INSTALLATION[AW6A-EL, AW6AX-EL].)
INSPECTION[AW6A-EL, AW6AX-EL].) No Inspect the coupler component.
— Shift solenoid C If normal, replace the control valve body.
— Shift solenoid D (See 05-17-38 CONTROL VALVE BODY REMOVAL/
— Shift solenoid E INSTALLATION[AW6A-EL, AW6AX-EL].)
— Shift solenoid F
— Line pressure control solenoid
• Are these normal?
4 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
05-03–11
1871-1U-06B(05-03).fm 12 ページ 2006年3月15日 水曜日 午前11時19分
Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
Diagnostic procedure
STEP INSPECTION ACTION
1 • Does the vehicle creep when selector lever is Yes Go to the next step.
moved slightly in N position? No Inspect and adjust the selector lever.
(See 05-18-6 SELECTOR LEVER INSPECTION.)
(See 05-18-7 SELECTOR CABLE ADJUSTMENT.)
Perform N position learning.
(See 05-17-25 TCM REMOVAL/INSTALLATION[AW6A-EL,
AW6AX-EL].)
2 • Inspect following solenoid. Yes Replace the ATX (clutch slippage, worm).
(See 05-17-20 SOLENOID VALVE (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
INSPECTION[AW6A-EL, AW6AX-EL].) INSTALLATION[AW6A-EL, AW6AX-EL].)
— Shift solenoid C No Inspect the coupler component.
— Shift solenoid D If normal, replace the control valve body.
• Are these solenoids normal? (See 05-17-38 CONTROL VALVE BODY REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
3 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
NO.3 VEHICLE MOVES IN P POSITION, OR PARKING GEAR DOES NOT DISENGAGE WHEN P IS
DISENGAGED[AW6A-EL, AW6AX-EL]
id050310800800
3 Vehicle moves in P position, or parking gear does not disengage when P is disengaged
• Vehicle rolls on a downward slope in P position.
DESCRIPTION • Tires are locked when P is disengaged. Vehicle does not move in D range, and R position when the
accelerator pedal is depressed, and the engine remains in a stalled condition.
• Parking mechanism malfunction (May have effect on noise or shock from transaxle)
POSSIBLE
• Improper adjustment of selector lever
CAUSE
• If the vehicle moves in N position, perform No.2 “VEHICLE MOVES IN N POSITION”
End Of Sie
NO.4 EXCESSIVE CREEP[AW6A-EL, AW6AX-EL]
id050310800900
4 Excessive creep
DESCRIPTION • Vehicle accelerates in D range, and R position when accelerator pedal is not depressed.
• Engine idle speed is high (transaxle system is not cause of problem)
POSSIBLE
• Go to No.9 “FAST IDLE/RUNS ON”
CAUSE
(See 01-03-37 NO.9 FAST IDLE/RUNS ON[L3 WITH TC].)
05-03–12
1871-1U-06B(05-03).fm 13 ページ 2006年3月15日 水曜日 午前11時19分
5 No creep at all
DESCRIPTION • Vehicle does not move in D range and R position when idling on a flat paved road.
• Either engine output low or there is clutch slippage.
— Clutch burnt (C1 clutch, C3 clutch)
• Line pressure low
• Shift solenoid C malfunction
• Shift solenoid D malfunction
• Shift solenoid E malfunction
• Line pressure control solenoid malfunction
• Shift solenoid F malfunction
• Body GND malfunction
• Control valve body malfunction
POSSIBLE — Transaxle fixed in 3GR or 5GR* (Operation of fail-safe function)
CAUSE • Short or open circuit in wiring harness
• Poor connection of connector
• Malfunction of electronic parts of output and input system
— There is no engine torque 05-03
• Torque converter malfunction
Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
Diagnostic procedure
STEP INSPECTION ACTION
1 • Does the vehicle creep in P and/or N Yes Inspect or adjust the selector lever.
position? (See 05-18-6 SELECTOR LEVER INSPECTION.)
(See 05-18-7 SELECTOR CABLE ADJUSTMENT.)
No Go to the next step.
2 • Stop the engine. Yes Go to the next step.
• Inspect following solenoid. No Inspect the coupler component.
(See 05-17-20 SOLENOID VALVE If normal, replace the control valve body.
INSPECTION[AW6A-EL, AW6AX-EL].) (See 05-17-38 CONTROL VALVE BODY REMOVAL/
— Shift solenoid C INSTALLATION[AW6A-EL, AW6AX-EL].)
— Shift solenoid D
— Shift solenoid E
— Shift solenoid F
— Line pressure control solenoid
• Are these solenoids normal?
3 • Remove the torque converter. Yes Inspect the ATF condition.
(See 05-17-46 TORQUE CONVERTER • If a large amount of metal specks are found, replace the
REMOVAL/INSTALLATION[AW6A-EL, transaxle.
AW6AX-EL].) (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
• Inspect the torque converter. INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is the torque converter normal? • If a large amount of metal specks are not found, replace
the control valve body.
(See 05-17-38 CONTROL VALVE BODY REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
No Replace the torque converter.
4 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
05-03–13
1871-1U-06B(05-03).fm 14 ページ 2006年3月15日 水曜日 午前11時19分
Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
Diagnostic procedure
STEP INSPECTION ACTION
1 • With the ignition switch at the ON position, Yes Go to the next step.
does the gear position indicator light No Go to No.27 “GEAR POSITION INDICATOR LIGHT DOES
indication correspond to the selector lever NOT ILLUMINATE IN M RANGE”, or No.28 “GEAR
position? POSITION INDICATOR LIGHT ILLUMINATES IN D RANGE
OR P, N, R POSITIONS”.
2 • Go to No.12 “LACK/LOSS OF POWER Yes Go to the next step.
(ACCELERATION/CRUISE)”. No Repair or replace any malfunctioning parts according to the
(See 01-03-46 NO.12 LACK/LOSS OF inspection results.
POWER (ACCELERATION/CRUISE)[L3
WITH TC].)
• Does engine control system normal?
3 • Stop the engine. Yes Go to the next step.
• Inspect following solenoid. No Inspect the coupler component.
(See 05-17-20 SOLENOID VALVE If normal, replace the control valve body.
INSPECTION[AW6A-EL, AW6AX-EL].) (See 05-17-38 CONTROL VALVE BODY REMOVAL/
— Shift solenoid C INSTALLATION[AW6A-EL, AW6AX-EL].)
— Shift solenoid D
— Shift solenoid E
— Shift solenoid F
— Line pressure control solenoid
• Are they normal?
4 • Remove the torque converter. Yes Inspect the ATF condition.
(See 05-17-46 TORQUE CONVERTER • If a large amount of metal specks are found, replace the
REMOVAL/INSTALLATION[AW6A-EL, transaxle.
AW6AX-EL].) (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
• Inspect the torque converter. INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is the torque converter normal? • If a large amount of metal specks are not found, replace
the control valve body.
(See 05-17-38 CONTROL VALVE BODY REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
No Replace the torque converter.
05-03–14
1871-1U-06B(05-03).fm 15 ページ 2006年3月15日 水曜日 午前11時19分
End Of Sie
NO.7 NO SHIFTING[AW6A-EL, AW6AX-EL]
id050310801200
7 No shifting
• Single shift range only.
DESCRIPTION
• Sometimes it shifts correctly.
• When the gear position is fixed in 3GR or 5GR* due to the fail-safe operation, malfunction is in the ATX.
• Perform malfunction diagnosis according to No.6 “LOW MAXIMUM SPEED AND POOR
ACCELERATION”. 05-03
— Clutch burnt (C1 clutch, C2 clutch, C3 clutch, B1 brake)
• Line pressure low
• Incorrect accelerator opening signal
• VSS malfunction
• Input/turbine speed sensor malfunction
• Sensor GND malfunction
POSSIBLE • Shift solenoid C malfunction
CAUSE • Shift solenoid D malfunction
• Shift solenoid E malfunction
• Line pressure control solenoid malfunction
• Shift solenoid F malfunction
• Control valve body malfunction
— 3GR or 5GR* is fixed (Operation in fail-safe function)
• Short or open circuit in wiring harness
• Poor connection of connector
• Poor ground of shift solenoid
• Malfunction of electronic parts of output and input system
End Of Sie
05-03–15
1871-1U-06B(05-03).fm 16 ページ 2006年3月15日 水曜日 午前11時19分
Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
Diagnostic procedure
STEP INSPECTION ACTION
1 • With the ignition switch at the ON position. Yes Go to the next step.
• Does the gear position indicator light No Go to No.27 “GEAR POSITION INDICATOR LIGHT DOES
indication correspond to selector lever NOT ILLUMINATE IN M RANGE”, or No.28 “GEAR
position? POSITION INDICATOR LIGHT ILLUMINATES IN D RANGE
OR P, N, R POSITIONS”.
2 • Drive the vehicle in D range and inspect Yes Go to the next step.
following: No No shift at all:
— 1–2 shift up and down • Go to No.7 “NO SHIFTING”.
— 2–3 shift up and down Abnormal shift:
— 3–4 shift up and down • Go to No.9 “ABNORMAL SHIFTING”.
— 4–5 shift up and down
— 5–6 shift up and down
• Are all shift-up and shift-down possible?
3 • Stop the engine. Yes Go to the next step.
• Inspect following solenoid. No Inspect for shift solenoid stuck.
(See 05-17-20 SOLENOID VALVE (See 05-17-20 SOLENOID VALVE INSPECTION[AW6A-EL,
INSPECTION[AW6A-EL, AW6AX-EL].) AW6AX-EL].)
— Shift solenoid C
— Shift solenoid D
— Shift solenoid E
— Shift solenoid F
— Line pressure control solenoid
• Are they normal?
05-03–16
1871-1U-06B(05-03).fm 17 ページ 2006年3月15日 水曜日 午前11時19分
9 Abnormal shifting
DESCRIPTION • Shift incorrectly (incorrect shift pattern).
• There is a malfunction in the signal circuit which controls shifting (Accelerator opening signal, input/
turbine speed sensor, VSS), the control valve is stuck, or the clutch circuit is stuck.
— Clutch slippage, burnt (C1 clutch, C2 clutch, C3 clutch, B1 brake)
• Line pressure low
• Incorrect accelerator opening signal
• VSS malfunction
• Input/turbine speed sensor malfunction
• Sensor GND malfunction
• Shift solenoid C malfunction
• Shift solenoid D malfunction
POSSIBLE • Shift solenoid E malfunction
CAUSE • Line pressure control solenoid malfunction
• TCC control solenoid malfunction
• Shift solenoid F malfunction
• Body GND malfunction
• Control valve body malfunction
• TR switch adjustment incorrect
Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
Diagnostic procedure
STEP INSPECTION ACTION
1 • Inspect for continuity between the TCM Yes Go to the next step.
terminal A9 and battery negative terminal. No Repair or replace ground circuit.
• Is there continuity?
2 • Inspect following shift solenoids. Yes Inspect the TCM terminal for bend, damage, corrosion or
(See 05-17-20 SOLENOID VALVE poor contact.
INSPECTION[AW6A-EL, AW6AX-EL].) No Inspect the coupler component.
— Shift solenoid C If normal, replace the control valve body.
— Shift solenoid D (See 05-17-38 CONTROL VALVE BODY REMOVAL/
— Shift solenoid E INSTALLATION[AW6A-EL, AW6AX-EL].)
— Line pressure control solenoid
— TCC control solenoid
— Shift solenoid F
• Are they normal?
3 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
05-03–17
1871-1U-06B(05-03).fm 18 ページ 2006年3月15日 水曜日 午前11時19分
10 Frequent shifting
DESCRIPTION • Downshifting occurs suddenly even when accelerator pedal is depressed slightly in D range.
• The malfunctioning circuit is basically the same as No.9 “ABNORMAL SHIFTING”. However, a
POSSIBLE malfunction of the input signal to the accelerator pedal position sensor, APP sensor, input/turbine speed
CAUSE sensor, VSS (including the sensor GND, sensor wiring harness and connector), or clutch slippage
(clutch stuck, low pressure in line) may also be the cause.
End Of Sie
NO.11 SHIFT POINT IS HIGH OR LOW[AW6A-EL, AW6AX-EL]
id050310801600
End Of Sie
NO.12 TORQUE CONVERTER CLUTCH (TCC) NON-OPERATION[AW6A-EL, AW6AX-EL]
id050310801700
Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
Diagnostic procedure
STEP INSPECTION ACTION
1 • With the ignition switch at the ON position. Yes Go to the next step.
• Does the gear position indicator light No Go to No.27 “GEAR POSITION INDICATOR LIGHT DOES
indication correspond to the selector lever NOT ILLUMINATE IN M RANGE”, or No.28 “GEAR
position? POSITION INDICATOR LIGHT ILLUMINATES IN D RANGE
OR P, N, R POSITIONS”.
2 • Disconnect the TCM. Yes Go to the next step.
• Is the resistance between the TCM ground No Repair open ground circuit.
terminal A9 and the body GND less than 5.0
ohms?
05-03–18
1871-1U-06B(05-03).fm 19 ページ 2006年3月15日 水曜日 午前11時19分
End Of Sie
NO.13 NO KICKDOWN[AW6A-EL, AW6AX-EL]
id050310801800
13 No kickdown
DESCRIPTION • Does not downshift when accelerator pedal is fully depressed within kickdown range.
• If transaxle does not downshift though shifting is normal, the malfunction is in the accelerator pedal
POSSIBLE
position sensor and accelerator pedal position sensor circuits (including sensor GND, sensor wiring
CAUSE
harness and connector).
End Of Sie
NO.14 ENGINE FLARES UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING[AW6A-EL, AW6AX-EL]
id050310801900
Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
05-03–19
1871-1U-06B(05-03).fm 20 ページ 2006年3月15日 水曜日 午前11時19分
End Of Sie
NO.15 ENGINE FLARES UP OR SLIPS WHEN ACCELERATING VEHICLE[AW6A-EL, AW6AX-EL]
id050310802000
End Of Sie
05-03–20
1871-1U-06B(05-03).fm 21 ページ 2006年3月15日 水曜日 午前11時19分
End Of Sie
NO.17 EXCESSIVE SHIFT SHOCK FROM N TO D OR N TO R POSITION/RANGE[AW6A-EL, AW6AX-EL]
id050310802200
Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
Diagnostic procedure
STEP INSPECTION ACTION
1 • Does the shift shock occur only when the Yes Go to the next step.
engine is cold? No Go to Step 3.
2 • Inspect the TFT sensor and related wiring Yes Go to the next step.
harness: vibration, intermittent open/short No Repair or replace part if necessary.
circuit.
(See 05-17-12 TRANSAXLE FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION[AW6A-EL, AW6AX-EL].)
• Is it normal?
3 • Perform the initial learning procedure. Yes Troubleshooting is completed.
(See 05-03-22 Initial Learning.) No Go to the next step.
• Does symptom eliminate?
4 • Is the line pressure normal? Yes Go to the next step.
(See 05-17-3 MECHANICAL SYSTEM No Repair or replace any malfunctioning parts according to the
TEST[AW6A-EL, AW6AX-EL].) inspection results.
05-03–21
1871-1U-06B(05-03).fm 22 ページ 2006年3月15日 水曜日 午前11時19分
Initial Learning
Warning
• When performing initial learning, be aware of other vehicles, people, and other impediments in
order to avoid an accident.
Note
• While self-learning control gradually reduces shock during normal driving, initial learning is performed to
initially learn a certain amount of driving conditions.
1. Warm-up
• Increase the ATF temperature by leaving the vehicle idling or performing city driving. Verify that the ATF
temperature is between 66— 110 °C {151— 230 °F}. If the ATF temperature is outside this range, work to
bring it inside the range.
Caution
• Do not raise the ATF temperature by stalling the engine.
Note
• If the ATF temperature is not between 66— 110 °C {151— 230 °F}, initial learning cannot be performed.
Before learning, inspect for variable shift shock.
05-03–22
1871-1U-06B(05-03).fm 23 ページ 2006年3月15日 水曜日 午前11時19分
End Of Sie
NO.19 EXCESSIVE SHIFT SHOCK ON TORQUE CONVERTER CLUTCH (TCC)[AW6A-EL, AW6AX-EL]
id050310802400
End Of Sie
NO.20 NOISE OCCURS AT IDLE WHEN VEHICLE IS STOPPED IN ALL POSITIONS/RANGES[AW6A-EL,
AW6AX-EL]
id050310802500
Note
• If a noise is emitted during shifting only, the malfunction is in the C1 clutch, C2 clutch, C3 clutch
POSSIBLE
or B1 brake.
CAUSE
• If a noise is emitted during shifting at certain gears only or during deceleration only, it is gear
noise.
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
Diagnostic procedure
STEP INSPECTION ACTION
1 • Inspect engine condition. Yes Go to appropriate symptom troubleshooting.
• Is there any engine concern (e.g. Rough (See 01-03-5 ENGINE SYMPTOM
idle)? TROUBLESHOOTING[L3 WITH TC].)
No Replace basic inspection and repair or replace any
malfunctioning parts according to the inspection result
2 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
05-03–23
1871-1U-06B(05-03).fm 24 ページ 2006年3月15日 水曜日 午前11時19分
End Of Sie
NO.22 NO ENGINE BRAKING IN 1GR POSITION OF M RANGE[AW6A-EL, AW6AX-EL]
id050310802700
Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
Diagnostic procedure
STEP INSPECTION ACTION
1 • Do the following symptoms occur Yes Go to No.14 “ENGINE FLARES UP OR SLIPS WHEN
concurrently? UPSHIFTING OR DOWNSHIFTING”, or No.15 “ENGINE
— Engine flares up or slips during FLARES UP OR SLIPS WHEN ACCELERATING
acceleration VEHICLE”.
— Engine flares up or slips when shifting No Go to the next step.
2 • Stop the engine. Yes Inspect the ATF condition.
• Inspect following solenoids. • If a large amount of metal specks are found, replace the
(See 05-17-20 SOLENOID VALVE transaxle.
INSPECTION[AW6A-EL, AW6AX-EL].) (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
— Shift solenoid A INSTALLATION[AW6A-EL, AW6AX-EL].)
— Shift solenoid B • If a large amount of metal specks are not found, replace
• Are the normal? the control valve body.
(See 05-17-38 CONTROL VALVE BODY REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
No Replace the control valve body.
(See 05-17-38 CONTROL VALVE BODY REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
3 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
05-03–24
1871-1U-06B(05-03).fm 25 ページ 2006年3月15日 水曜日 午前11時19分
23 TRANSAXLE OVERHEATS
• Burnt smell emitted from transaxle.
DESCRIPTION
• Smoke emitted from transaxle.
• The malfunction is restricted to the hindrance of coolant at the oil cooler. In addition, overheating of the
transaxle may be caused by a malfunction of the TFT sensor.
— Line pressure low
• ATF level low
• Incorrect accelerator opening signal
— Oil cooler malfunction (Foreign material mixed in with ATF)
POSSIBLE — TFT sensor malfunction
CAUSE — Excessive amount of ATF
Note
• Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
05-03
Diagnostic procedure
STEP INSPECTION ACTION
1 • Is the line pressure normal? Yes Go to the next step.
(See 05-17-3 MECHANICAL SYSTEM No Repair or replace any malfunctioning parts according to the
TEST[AW6A-EL, AW6AX-EL].) inspection results.
2 • Is stall speed normal? Yes Go to the next step.
(See 05-17-3 MECHANICAL SYSTEM No Repair or replace any malfunctioning parts according to the
TEST[AW6A-EL, AW6AX-EL].) inspection results.
3 • Inspect the TFT sensor and related wiring Yes Go to the next step.
harness: vibration, intermittent open/short No Repair or replace part if necessary.
circuit
(See 05-17-12 TRANSAXLE FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION[AW6A-EL, AW6AX-EL].)
• Is it normal?
4 • Inspect the line pressure control solenoid. Yes Go to the next step.
(See 05-17-20 SOLENOID VALVE No Replace the control valve body.
INSPECTION[AW6A-EL, AW6AX-EL].) (See 05-17-38 CONTROL VALVE BODY REMOVAL/
• Is it normal? INSTALLATION[AW6A-EL, AW6AX-EL].)
5 • Inspect for bending, damage, corrosion or Yes Replace the transaxle.
kinks of the oil cooler pipes. (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
• Are oil cooler pipes normal? INSTALLATION[AW6A-EL, AW6AX-EL].)
No Replace any malfunctioning parts.
6 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
05-03–25
1871-1U-06B(05-03).fm 26 ページ 2006年3月15日 水曜日 午前11時19分
Diagnostic procedure
STEP INSPECTION ACTION
1 • Go to symptom troubleshooting No.5 Yes Go to the next step.
“ENGINE STALLS-AFTER START/AT IDLE”. No Repair or replace any malfunctioning parts according to the
(See 01-03-23 NO.5 ENGINE STALLS- inspection results.
AFTER START/AT IDLE[L3 WITH TC].)
• Is the engine control system normal?
2 • Remove the torque converter. Yes Inspect for bending, damage, corrosion or kinks of the oil
(See 05-17-46 TORQUE CONVERTER cooler pipes.
REMOVAL/INSTALLATION[AW6A-EL, • If normal, replace the control valve body.
AW6AX-EL].) (See 05-17-38 CONTROL VALVE BODY REMOVAL/
• Inspect the torque converter. INSTALLATION[AW6A-EL, AW6AX-EL].)
• Is the torque converter normal? • If problem remains, replace the transaxle.
(See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
No Replace the torque converter.
3 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
NO.25 ENGINE STALLS WHEN DRIVING AT SLOW SPEED OR STOPPING[AW6A-EL, AW6AX-EL]
id050310803000
Diagnostic procedure
STEP INSPECTION ACTION
1 • Go to symptom troubleshooting No.10 “LOW Yes Go to No.24 “ENGINE STALLS WHEN SHIFTED TO D
IDLE/STALLS DURING DECELERATION”. RANGE, OR IN R POSITION”.
(See 01-03-39 NO.10 LOW IDLE/STALLS No Repair or replace any malfunctioning parts according to the
DURING DECELERATION[L3 WITH TC].) inspection results.
• Is the engine control system normal?
2 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
05-03–26
1871-1U-06B(05-03).fm 27 ページ 2006年3月15日 水曜日 午前11時19分
Diagnostic procedure
STEP INSPECTION ACTION
1 • Perform the N position learning. Yes Troubleshooting is completed.
(See 05-17-25 TCM REMOVAL/ If the other symptom occurs, go to applicable
INSTALLATION[AW6A-EL, AW6AX-EL].) troubleshooting procedure.
• Does the problem eliminate? No Go to the next step.
2 • Inspect the TR switch. Yes Go to engine system troubleshooting No.3 “WILL NOT
(See 05-17-11 TRANSAXLE RANGE (TR) CRANK” troubleshooting procedure. 05-03
SWITCH INSPECTION[AW6A-EL, AW6AX- No Replace the TR switch and perform initial learning
EL].) procedure.
• Is the TR switch normal? (See 05-03-21 NO.17 EXCESSIVE SHIFT SHOCK FROM N
TO D OR N TO R POSITION/RANGE[AW6A-EL, AW6AX-
EL].)
3 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
NO.27 GEAR POSITION INDICATOR LIGHT DOES NOT ILLUMINATE IN M RANGE[AW6A-EL, AW6AX-EL]
id050310803200
POSSIBLE Note
CAUSE • Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
Diagnostic procedure
STEP INSPECTION ACTION
1 • Do other indicator lights illuminate with the Yes Go to the next step.
ignition switch at ON? No Inspect the meter fuse.
2 • Inspect the voltage at the TCM terminal A7. Yes Inspect the instrument cluster.
(See 05-17-21 TCM INSPECTION[AW6A- No Inspect the M range switch.
EL, AW6AX-EL].) If the M range switch is normal, inspect for continuity
• Is the voltage normal? between the M range switch and TCM terminal A7.
3 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
05-03–27
1871-1U-06B(05-03).fm 28 ページ 2006年3月15日 水曜日 午前11時19分
POSSIBLE Note
CAUSE • Before following the troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted. (See 05-03-3 BASIC
INSPECTION[AW6A-EL, AW6AX-EL].)
Diagnostic procedure
STEP INSPECTION ACTION
1 • Inspect the voltage at the TCM terminal A7. Yes Inspect the instrument cluster.
(See 05-17-21 TCM INSPECTION[AW6A- No Inspect the M range switch.
EL, AW6AX-EL].) If the M range switch is normal, inspect for continuity
• Is the voltage normal? between the M range switch and TCM terminal A7.
2 • Verify test results.
— If normal, return to the diagnostic index to service any additional symptoms.
— If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
• If the vehicle is repaired, troubleshooting completed.
• If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
End Of Sie
NO.29 DOES NOT UPSHIFT IN M RANGE[AW6A-EL, AW6AX-EL]
id050310803400
05-03–28
1871-1U-06B(05-03).fm 29 ページ 2006年3月15日 水曜日 午前11時19分
05-03
05-03–29
1871-1U-06B(05-17).fm 1 ページ 2006年3月15日 水曜日 午前11時20分
End of Toc
05-17–1
1871-1U-06B(05-17).fm 2 ページ 2006年3月15日 水曜日 午前11時20分
id051723802000
10 7
11
13
12
6
15
8
14
4 3
acxuuw00000486
.
05-17–2
1871-1U-06B(05-17).fm 3 ページ 2006年3月15日 水曜日 午前11時20分
End Of Sie
MECHANICAL SYSTEM TEST[AW6A-EL, AW6AX-EL]
id051723802100
Mechanical System Test Preparation
1. Engage the parking brake and use wheel chocks at the front and rear of the wheels.
2. Inspect the engine coolant level. (See 01-12-2 COOLING SYSTEM SERVICE WARNINGS[L3 WITH TC].) (See
01-12-3 ENGINE COOLANT LEVEL INSPECTION[L3 WITH TC].)
3. Inspect the engine oil level. (See 01-11-3 ENGINE OIL LEVEL INSPECTION[L3 WITH TC].)
4. Inspect the ATF level. (See 05-17-10 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION[AW6A-EL,
AW6AX-EL].)
5. Inspect the idle speed. (See 01-10-35 ENGINE TUNE-UP[L3 WITH TC].)
6. Inspect the ignition timing. (See 01-10-35 ENGINE TUNE-UP[L3 WITH TC].)
05-17–3
1871-1U-06B(05-17).fm 4 ページ 2006年3月15日 水曜日 午前11時20分
D, M RANGE R POSITION
49 0378 400C
49 0378 400C
acxuuw00000479
4. Start the engine and warm it up until the ATF reaches 60— 70 °C {140— 158 °F}.
5. Shift the selector lever to the D range.
Caution
• Perform the test at least 3 times and calculate the average.
6. Read the line pressure while the engine is idling for the D range.
7. Read the line pressure while the engine is idling for the R position and M range in the same manner as in Steps
4— 5.
Line pressure
Position/range Line pressure (kPa {kgf/cm2, psi})
D, M Idle 350— 410 {3.6— 4.1, 51— 59}
R Idle 580— 670 {6.0— 6.8, 85— 97}
8. Stop the engine, then replace the SST (49 B019 901B) with the gauge of the SST (49 0378 400C).
9. Connect the M-MDS to the DLC-2.
10. Measure the LPS PID value.
11. Start the engine.
12. Firmly depress the brake pedal with the left foot.
13. Shift the selector lever to the D range.
Caution
• If the accelerator pedal is pressed for
more than 5 s while the brake pedal is
pressed, the transaxle could be
damaged. Therefore, perform Steps 13
DLC-2
and 14 within 5 s.
acxuuw00000480
05-17–4
1871-1U-06B(05-17).fm 5 ページ 2006年3月15日 水曜日 午前11時20分
500
{5.1, 73} 300 CURRENT 300
{5.1, 73}
05-17
IDLE STALL
THROTTLE OPENING
acxuuw00000481
Warning
• Removing the SST when the ATF is hot can be dangerous. Hot ATF can come out of the opening
and badly burn you. Before removing the SST, allow the ATF to cool.
Tightening torque
5.9— 8.8 N·m {61— 89 kgf·cm, 53— 77 in·lbf}
Stall Test
1. Perform mechanical system test preparation. (See 05-17-3 Mechanical System Test Preparation.)
2. Start the engine.
3. Firmly depress the brake pedal with the left foot.
4. Shift the selector lever to the D range.
Caution
• If the accelerator pedal is depressed for more than 5 s while the brake pedal is depressed, the
transaxle could be damaged. Therefore, perform Steps 5 and 6 within 5 s.
• Perform the test at least 3 times and calculate the average.
05-17–5
1871-1U-06B(05-17).fm 6 ページ 2006年3月15日 水曜日 午前11時20分
Formula
Average time lag = (Time 1 + Time 2 + Time 3) / 3
6. Perform the test for the following shifts in the same manner as in Step 5.
• N position → R position
End Of Sie
05-17–6
1871-1U-06B(05-17).fm 7 ページ 2006年3月15日 水曜日 午前11時20分
Warning
• When performing a road test, be aware of other vehicles, people, and other impediments in order
to avoid an accident.
Note
• When the legal speed limit must be exceeded, use a chassis dynamometer instead of performing a road
test.
Shift Diagram
D range (normal mode)
5/8
4/8
3/8
2/8
SHIFT UP
1/8
SHIFT DOWN
0/8
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230
{0} {6.2} {12} {19} {25} {31} {37} {43} {50} {56} {62} {68} {74} {81} {87} {93} {99} {105} {112} {118} {124} {131} {137} {143}
acxuuw00000482
05-17–7
1871-1U-06B(05-17).fm 8 ページ 2006年3月15日 水曜日 午前11時20分
05-17–8
1871-1U-06B(05-17).fm 9 ページ 2006年3月15日 水曜日 午前11時20分
M Range Test
1. Perform road test preparation. (See05-17-7 Road Test Preparation.)
2. Shift the selector lever to M range.
3. Verify that 1→2, 2→3, 3→4, 4→5 and 5→6 upshifts and 6→5, 5→4, 4→3, 3→2, and 2→1 downshifts are
obtained by manual shifting of the selector lever forward and back.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE[AW6A-EL, AW6AX-EL].)
4. Decelerate the vehicle and verify that 6→5, 5→4, 4→3, 3→1 downshifts are obtained. The shift points must be
as shown in the table below.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE[AW6A-EL, AW6AX-EL].)
5. Decelerate the vehicle and verify that engine braking effect is felt in 1GR.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE[AW6A-EL, AW6AX-EL].)
6. Drive the vehicle and verify that TCC operation is obtained in 4GR, 5GR and 6GR. The operation points must
be as shown in the table below.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE[AW6A-EL, AW6AX-EL].)
7. Drive the vehicle in 6GR, 5GR, 4GR and 3GR and verify that kickdown occurs for 6→5, 5→4, 4→3, 3→2
downshifts, and that the shift points are as shown in the table below.
• If there is any malfunction, inspect the TCM and ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING
ITEM TABLE[AW6A-EL, AW6AX-EL].)
05-17–9
1871-1U-06B(05-17).fm 10 ページ 2006年3月15日 水曜日 午前11時20分
P Position Test
1. Shift into P position on a gentle slope. Release the brake and verify that the vehicle does not roll.
• If there is any malfunction, inspect the ATX. (See 05-03-4 SYMPTOM TROUBLESHOOTING ITEM
TABLE[AW6A-EL, AW6AX-EL].)
End Of Sie
AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION[AW6A-EL, AW6AX-EL]
WM: AUTOMATIC TRANSMISSION/TRANSAXLE FLUID
id051723800500
Automatic Transaxle Fluid (ATF) Condition Inspection
1. Inspect the ATF for the following to determine whether the transaxle should be disassembled.
• The ATF is muddy.
• The ATF smells strange or unusual.
ATF Condition
Condition Possible cause
Clear dark red Normal —
• Damaged oil cooler
• Poor filler tube installation:
Light red (pink) Contaminated with water Problem could occur to parts inside the transaxle due
to water contamination.
If necessary, replace the transaxle.
Defective powertrain components inside the transaxle:
Particles cause wide range of problems by clogging
the oil pipe, control valve body and oil cooler.
Has burnt smell and metal
Reddish Deteriorated ATF • A large amount of metal particles are found.
particles are found
brown If necessary, replace the transaxle.
• Flush the system due to possible clogging of the oil
pipe or oil cooler.
Has no burnt smell Normal • Discoloration by oxidation
Caution
• The ATF amount varies according to ATF temperature. Therefore, when checking the ATF level or
replacing the ATF, use a thermometer to measure the temperature and adjust the ATF amount to
the specified level according to the specified temperature.
05-17–10
1871-1U-06B(05-17).fm 11 ページ 2006年3月15日 水曜日 午前11時20分
ATF TEMPERATURE
15—25 ˚C {59—77 ˚F}
acxuuw00000485
Warning
• A hot transaxle and ATF can cause severe burns. Turn off the engine and wait until they are cool
before replacing the ATF.
Tightening torque
23.5— 54.9 N·m {2.4— 5.5 kgf·m, 17.4— 40.4
ft·lbf}
ATF
ampjjw00001890
Type: JWS3309
Capacity (Approx. quantity): 7.0 L {7.4 US qt,
6.2 lmp qt}
id051723800900
Note
• TR switch function is installed as one part of TCM.
05-17–11
1871-1U-06B(05-17).fm 12 ページ 2006年3月15日 水曜日 午前11時20分
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.
Off-Vehicle Inspection
Warning
• A hot transaxle and ATF can cause severe burns. Turn off the engine and wait until they are cool
before replacing the ATF.
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.
05-17–12
1871-1U-06B(05-17).fm 13 ページ 2006年3月15日 水曜日 午前11時20分
B4 B3 B2 B1
B11 B10 B9 B8 B7 B5
B18 B17 B16 B14 B13 B12
B22 B21 B20 B19
acxuuw00000490
05-17
11. Install the TFT sensor. (See 05-17-13 TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
12. Install the control valve body. (See 05-17-38 CONTROL VALVE BODY REMOVAL/INSTALLATION[AW6A-EL,
AW6AX-EL].)
13. Install the thermo valve. (See 05-17-47 OIL COOLER REMOVAL/INSTALLATION[AW6A-EL, AW6AX-EL].)
14. Install the resonance chamber. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
15. Add ATF to the specified level. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
REPLACEMENT[AW6A-EL, AW6AX-EL].)
16. Install the under cover.
17. Install the air cleaner component. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH
TC].)
18. Connect the negative battery cable.
End Of Sie
TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR REMOVAL/INSTALLATION[AW6A-EL, AW6AX-EL]
id051723801100
Warning
• A hot transaxle and ATF can cause severe burns. Turn off the engine and wait until they are cool
before replacing the ATF.
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.
05-17–13
1871-1U-06B(05-17).fm 14 ページ 2006年3月15日 水曜日 午前11時20分
R
acxuuw00000489
Caution
• Do not damage the wiring harness.
• Do not pull hard on the wiring harness.
acxuuw00000491
acxuuw00000492
Caution
• Do not apply too much force to the
coupler component. O-RING
• Do not damage the coupler component.
acxuuw00000492
05-17–14
1871-1U-06B(05-17).fm 15 ページ 2006年3月15日 水曜日 午前11時20分
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.
Note
• Inspect with a tester that can indicate more
acxuuw00000498
than 10 megohms and confirm that the
value is more than 1 megohm.
05-17–15
1871-1U-06B(05-17).fm 16 ページ 2006年3月15日 水曜日 午前11時20分
Warning
• A hot transaxle and ATF can cause severe burns. Turn off the engine and wait until they are cool
before replacing the ATF.
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.
1 2
acxuuw00000499
MAGNET
SHAKING DIRECTION
acxuuw00000500
05-17–16
1871-1U-06B(05-17).fm 17 ページ 2006年3月15日 水曜日 午前11時20分
11. Install the input/turbine speed sensor. (See 05-17-17 INPUT/TURBINE SPEED SENSOR REMOVAL/
INSTALLATION[AW6A-EL, AW6AX-EL].)
12. Install the control valve body. (See 05-17-38 CONTROL VALVE BODY REMOVAL/INSTALLATION[AW6A-EL,
AW6AX-EL].)
13. Install the thermo valve. (See 05-17-47 OIL COOLER REMOVAL/INSTALLATION[AW6A-EL, AW6AX-EL].)
14. Install the resonance chamber. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
15. Add ATF to the specified level. (See 05-17-11 AUTOMATIC TRANSAXLE FLUID (ATF)
REPLACEMENT[AW6A-EL, AW6AX-EL].)
16. Install the under cover.
17. Install the air cleaner component. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH
TC].)
18. Connect the negative battery cable.
19. Perform the mechanical system test. (See 05-17-3 MECHANICAL SYSTEM TEST[AW6A-EL, AW6AX-EL].) 05-17
End Of Sie
INPUT/TURBINE SPEED SENSOR REMOVAL/INSTALLATION[AW6A-EL, AW6AX-EL]
id051723801300
Warning
• A hot transaxle and ATF can cause severe burns. Turn off the engine and wait until then are cool
before replacing the ATF.
Caution
• Do not damage the input/turbine speed
sensor.
R
acxuuw00000489
Tightening torque
3.9— 6.9 N·m {40— 70 kgf·cm, 26— 60 in·lbf}
05-17–17
1871-1U-06B(05-17).fm 18 ページ 2006年3月15日 水曜日 午前11時20分
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.
Note
• Inspect with a tester that can indicatemore
acxuuw00000502
than 10 megohms and confirm that the
value is more than 1 megohm.
Off-Vehicle Inspection
Warning
• A hot transaxle and ATF can cause severe burns. Turn off the engine and wait until they are cool
before replacing the ATF.
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.
05-17–18
1871-1U-06B(05-17).fm 19 ページ 2006年3月15日 水曜日 午前11時20分
1 2
acxuuw00000499
MAGNET
SHAKING DIRECTION
acxuuw00000500
VSS
Signal Current (mA)
High 12.0— 16.0
Low 4.0— 8.0
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to drop water or foreign material on the connector when disconnecting it.
• If foreign materials are stuck to the VSS, disturbance by magnetic flux can cause sensor output to
be abnormal and thereby negatively affect control. Make sure that foreign materials such as iron
filings are not stuck to the VSS during installation.
05-17–19
1871-1U-06B(05-17).fm 20 ページ 2006年3月15日 水曜日 午前11時20分
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.
acxuuw00000508
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
• Do not damage the terminals.
05-17–20
1871-1U-06B(05-17).fm 21 ページ 2006年3月15日 水曜日 午前11時20分
Warning
• Be careful not to damage the connector waterproofing when measuring the TCM terminal voltage.
If damaged, the waterproofing efficiency could be negatively affected.
Note
• Use the ground of terminal A9 of the TCM connector (wiring harness-side) when measuring terminal
voltage, as an error may occur when connecting the negative circuit tester to ground.
A2 A1
A8 A7 A6 A5 A4 A3
acxuuw00000521
Terminal Signal Connected to Test condition Voltage (V) Inspection item (s)
Battery back up • Inspect battery
A1 Battery Constant B+
supply • Inspect related harness
Shift up • Inspect selector lever
Below 1.0
(M range) component
Up switch Up switch
(See 05-18-6 SELECTOR
A3 (Selector lever (Selector lever
Other ranges, all LEVER COMPONENT
component) component) B+
positions INSPECTION)
• Inspect related harness
05-17–21
1871-1U-06B(05-17).fm 22 ページ 2006年3月15日 水曜日 午前11時20分
05-17–22
1871-1U-06B(05-17).fm 23 ページ 2006年3月15日 水曜日 午前11時20分
acxuuw00000522
05-17
Continuity/
Terminal Signal Connected to Test Condition Inspection item (s)
Resistance
A9 System GND GND Constant Continuity • Inspect related harness
• Inspect • Inspect line pressure
resistance control solenoid
Line pressure
Line pressure between couple ATF (See 05-17-20
control 5.0— 5.6
B1 control component temperature: SOLENOID VALVE
solenoid (ohms)
solenoid terminals B3 20°C {68°F} INSPECTION[AW6A-EL,
control GND
and B1 (wiring AW6AX-EL])
harness-side). • Inspect related harness
• Inspect shift solenoid B
(See 05-17-20
Shift solenoid Shift solenoid 11— 15 SOLENOID VALVE
B2 ATF temperature: 20°C {68°F}
B control B (ohms) INSPECTION[AW6A-EL,
AW6AX-EL])
• Inspect related harness
• Inspect • Inspect line pressure
resistance control solenoid
Line pressure
Line pressure between couple ATF (See 05-17-20
control 5.0— 5.6
B3 control component temperature: SOLENOID VALVE
solenoid (ohms)
solenoid terminals B3 20°C {68°F} INSPECTION[AW6A-EL,
control
and B1 (wiring AW6AX-EL])
harness-side). • Inspect related harness
• Inspect • Inspect TCC control
resistance solenoid
TCC control between couple ATF (See 05-17-20
TCC control 5.0— 5.6
B4 solenoid component temperature: SOLENOID VALVE
solenoid (ohms)
control GND terminals B9 20°C {68°F} INSPECTION[AW6A-EL,
and B4 (wiring AW6AX-EL])
harness-side). • Inspect related harness
• Inspect shift solenoid A
(See 05-17-20
Shift solenoid Shift solenoid 11— 15 SOLENOID VALVE
B5 ATF temperature: 20°C {68°F}
A control A (ohms) INSPECTION[AW6A-EL,
AW6AX-EL])
• Inspect related harness
ATF
5.62— 7.31 • Inspect TFT sensor
• Inspect temperature:
(kilohms) (See 05-17-12
TFT sensor resistance 10°C {50°F}
B7 TRANSAXLE FLUID
GND between couple ATF
Approx. 3.5 TEMPERATURE (TFT)
TFT sensor component temperature:
(kilohms) SENSOR
terminals B7 25°C {77°F}
INSPECTION[AW6A-EL,
and B8 (wiring ATF
0.22— 0.27 AW6AX-EL])
harness-side).
B8 TFT sensor temperature:
(kilohms) • Inspect related harness
110°C {230°F}
05-17–23
1871-1U-06B(05-17).fm 24 ページ 2006年3月15日 水曜日 午前11時20分
05-17–24
1871-1U-06B(05-17).fm 25 ページ 2006年3月15日 水曜日 午前11時20分
End Of Sie
TCM REMOVAL/INSTALLATION[AW6A-EL, AW6AX-EL]
id051723800400
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
acxuuw00000523
WASHER
MANUAL
SHAFT
LEVER
TCM
acxuuw00000525
05-17–25
1871-1U-06B(05-17).fm 26 ページ 2006年3月15日 水曜日 午前11時20分
TCM
acxuuw00000526
Caution
• Do not touch the terminals.
acxuuw00000527
acxuuw00000528
acxuuw00000529
Caution
• Do not turn more than 60° from the
marking.
acxuuw00000530
05-17–26
1871-1U-06B(05-17).fm 27 ページ 2006年3月15日 水曜日 午前11時20分
Tightening torque
19.6— 29.4 N·m {2.0— 2.9 kgf·m, 14.5— 21.6
ft·lbf}
Caution
• Do not use an impact wrench. Hold the
manual shaft lever when removing the
manual shaft nut, or the transaxle may be
acxuuw00000531
damaged.
WASHER 05-17
MANUAL
SHAFT
LEVER
TCM
acxuuw00000525
15. Set the adjustable wrench as shown in the figure
to hold the manual shaft lever, and tighten the
manual shaft nut.
Tightening torque
9.8— 14.7 N·m {100— 142 kgf·cm, 87— 123
in·lbf}
CLIP
acxuuw00000532
19. Connect the selector cable and install the clip.
20. Connect the TCM connector.
CLIP
21. Install the air cleaner component. (See 01-13-5
INTAKE AIR SYSTEM REMOVAL/
INSTALLATION[L3 WITH TC].) TCM SELECTOR
22. Connect the negative battery cable. CABLE
Warning
• If you replace the ATX or TCM, be sure to MANUAL
initialize the learned values and perform SHAFT
neutral position learning. LEVER
23. Perform the neutral position learning. (See 05-17-
acxuuw00000523
28 Neutral Position Learning.)
05-17–27
1871-1U-06B(05-17).fm 28 ページ 2006年3月15日 水曜日 午前11時20分
id051723802300
Caution
• Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to allow water or foreign material on the connector when disconnecting.
Caution
• Do not damage the transaxle case.
• Do not damage the manual shaft.
Caution
• Do not damage the oil seal.
acxuuw00000533
05-17–28
1871-1U-06B(05-17).fm 29 ページ 2006年3月15日 水曜日 午前11時20分
Warning
• Improperly jacking a transaxle is dangerous. It can slip off the jack and may cause serious injury.
Caution
• To prevent the torque converter and transaxle from separating, remove the transaxle without
tilting it toward the torque converter.
05-17–29
1871-1U-06B(05-17).fm 30 ページ 2006年3月15日 水曜日 午前11時20分
7.8—10.8 N·m
{80—110 kgf·cm,
22 70—95 in·lbf}
8—11 N·m 40.5—54.7
{82—112 kgf·cm, {4.13—5.57,
17
71—97 in·lbf} 18 29.9—40.3}
38—51
{3.9—5.2, 29—37} 5
7.8—10.8 N·m
42—62
{80—110 kgf·cm,
{4.3—6.3, 31—45}
70—95 in·lbf}
4
66.6—93.1
{6.80—9.49,
37—52 49.2—68.6}
16 {3.8—5.3,
25.5—34.5 28—38}
{2.61—3.51,
18.9—25.4} 6
42—62 R
{4.3—6.3,
6 23
31—45} R 3 A
14 A
D
15
74.5—104.9
7.8—10.8 N·m
19 26 {7.60—10.69, 55.0—77.3}
1 {80—110 kgf·cm,
70—95 in·lbf}
2
R
R
93.1—116.6 19
{9.50—11.88,
D 68.7—85.9}
25 37—52
{3.8—5.3, 28—38} 14
85.3—116.6
7.8—10.8 N·m {8.70—11.88, B
{80—110 kgf·cm, 62.9—85.9} C
70—95 in·lbf} 11
47.0—59.0 12
{4.80—6.01,
34.7—43.5}
11
21 119.6—154.8
42.3—60.1 {12.20—15.78,
38—51 {4.32—6.12, 88.3—114.1}
{3.9—5.2,
20 9 93.1—131.3
31.2—44.3}
{9.50—13.38,
29—37} 8 68.7—96.8}
12
43.1—58.8 10 7
{4.40—5.99,
31.8—43.3} 18.6—26.5
{1.9—2.7,
14—19}
119.6—154.8
42.3—60.1
{12.20—15.78,
{4.32—6.12,
88.3—114.1}
31.2—44.3}
B
93.1—131.3
{9.50—13.38,
119.6—154.8 C 47.0—59.0
68.7—96.8}
{12.2—15.7, {4.80—6.01,
88.3—114.1} 34.7—43.5}
8
119.6—154.8 9
{12.2—15.7,
88.3—114.1}
13 10
43.1—58.8
{4.40—5.99,
4.2—6.2 N·m 31.8—43.3}
{43—63 kgf·cm, 119.6—154.8
38—54 in·lbf} 119.6—154.8 {12.2—15.7,
{12.2—15.7, 88.3—114.1} N·m {kgf·m, ft·lbf}
24 88.3—114.1}
acxuuw00000614
05-17–30
1871-1U-06B(05-17).fm 31 ページ 2006年3月15日 水曜日 午前11時20分
6.9—9.8 N·m 29
{71—99 kgf·cm,
62—86 in·lbf}
30
28
64—89
{6.6—9.0, 48—65}
27
64—89 19—27
{6.6—9.0, 48—65} {2.0—2.7, 15—19}
acxuuw00000615
05-17–31
1871-1U-06B(05-17).fm 32 ページ 2006年3月15日 水曜日 午前11時20分
acxuuw00000622
NUT
acxuuw00000632
Caution
MAIN FRAME
• Refer to the SST instruction manual for
the basic handing procedure.
REAR SHAFT
SIDE BAR
FRONT SHAFT
05-17–32
1871-1U-06B(05-17).fm 33 ページ 2006年3月15日 水曜日 午前11時20分
acxuuw00000224
05-17
(3) Temporarily tighten the air clear bracket
installation bolt, and install the left/right front LH
49 C017 5A0
shaft of the SST with front foot No.2 to the bolt
as shown in the figure.
(4) Adjust the positions of the SST side bars so
that they are the same height (left and right)
and horizontal.
(5) Make sure each joint is securely tightened.
RH
acxuuw00000225
acxuuw00000226
05-17–33
1871-1U-06B(05-17).fm 34 ページ 2006年3月15日 水曜日 午前11時20分
ampjjw00001617
A
A A
acxuuw00000633
Tightening torque
Bolt A, Nut B, C: 66.6— 93.1 N·m {6.80—
NUT C
9.49 kgf·m, 49.2— 68.6 ft·lbf}
Bolt D: 74.5— 104.9 N·m {7.60— 10.69 kgf·m,
acxuuw00000634
55.0— 77.3 ft·lbf}
Tightening torque
Bolt A, B: 93.1— 116.6 N·m
{9.50— 11.88 kgf·m, 68.7— 85.9 ft·lbf}
Bolt C: 85.3— 116.6 N·m BOLT C
{87.0— 11.88 kgf·m, 62.9— 85.9 ft·lbf}
acxuuw00000635
05-17–34
1871-1U-06B(05-17).fm 35 ページ 2006年3月15日 水曜日 午前11時20分
Caution
• Loosely and equally tighten the torque
converter nuts, then further tighten them
to the specified tightening torque.
acxuuw00000622
Tightening torque
34.3— 60.8 N·m {3.50— 6.19 kgf·m, 25.3— 05-17
44.8 ft·lbf}
NUT
acxuuw00000632
Caution
• The oil seal is easily damaged by the sharp edges of the drive shaft splines. Do not let the splines
contact the oil seal.
4. Remove the drive shaft. (See 03-13-12 FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)
5. Remove the joint shaft. (2WD) (See 03-13-3 JOINT SHAFT REMOVAL/INSTALLATION[2WD].)
6. Remove the transfer and joint shaft. (AWD) (See 03-13-4 JOINT SHAFT REMOVAL/INSTALLATION[AWD].)
(See 03-16-3 TRANSFER REMOVAL/INSTALLATION.)
Caution
• Do not damage the transaxle case.
• Do not damage the differential case.
05-17–35
1871-1U-06B(05-17).fm 36 ページ 2006年3月15日 水曜日 午前11時20分
Caution
• Do not damage the oil seal.
acxuuw00000536
acxuuw00002288
2.3—3.3 mm
{0.091—0.130 in}
acxuuw00002289
05-17–36
1871-1U-06B(05-17).fm 37 ページ 2006年3月15日 水曜日 午前11時20分
Caution
• The O-ring is easily damaged by the sharp edges of the drive shaft splines. Do not let the splines
contact the O-ring.
1. Remove the drive shaft and joint shaft. (See 03-13-3 JOINT SHAFT REMOVAL/INSTALLATION[2WD].) (See
03-13-4 JOINT SHAFT REMOVAL/INSTALLATION[AWD].) (See 03-13-12 FRONT DRIVE SHAFT REMOVAL/
INSTALLATION.)
Caution
• Do not damage the differential case.
Caution
• Do not damage the O-ring.
• Do not damage the differential case.
05-17–37
1871-1U-06B(05-17).fm 38 ページ 2006年3月15日 水曜日 午前11時20分
Warning
• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eyeglasses whenever using compressed air.
Caution
• Clean the transaxle exterior throughout with a steam cleaner or cleaning solvents before removal.
• If any old sealant gets into the transaxle during installation of the control valve body cover, trouble
may occur in the transaxle case and control valve body cover. Clean with cleaning fluid.
R
acxuuw00000489
Caution
• Do not damage the fitting surface of the
transaxle case and the control valve body
cover.
• Do not deform the control valve body
cover.
acxuuw00000585
05-17–38
1871-1U-06B(05-17).fm 39 ページ 2006年3月15日 水曜日 午前11時20分
Caution
• Be careful not to damage the solenoid
valves and connectors.
• Do not pull the wiring harnesses when
removing the connector.
Note
• Disconnect the solenoid connector
according to the following procedure:
acxuuw00000586
05-17
acxuuw00000587
Caution
• Do not damage the solenoid valves and
connectors with the screwdriver.
• When disconnecting connectors, grasp
the connectors, not the harnesses.
Otherwise, the harnesses may be pulled
out of the connector causing poor
contact.
acxuuw00000588
acxuuw00000589
05-17–39
1871-1U-06B(05-17).fm 40 ページ 2006年3月15日 水曜日 午前11時20分
Note
• Be sure to secure the coupler component
with tape so that it will not interfere with the
control valve body component.
acxuuw00000590
acxuuw00000591
acxuuw00000592
Note
• Be sure to secure the VSS and input/turbine speed sensor with tape so that they will not interfere with the
control valve body component.
acxuuw00000593
05-17–40
1871-1U-06B(05-17).fm 41 ページ 2006年3月15日 水曜日 午前11時20分
Caution
• Evenly loosen the bolts a little at a time in
the order shown in the figure.
acxuuw00000594
05-17
17. Remove the control valve body installation bolts.
Caution
2
• Do not drop the control valve body
component.
3
6
5
4 1
acxuuw00000595
acxuuw00000596
05-17–41
1871-1U-06B(05-17).fm 42 ページ 2006年3月15日 水曜日 午前11時20分
Caution
• When installing the control valve body component, do not put the coupler component in the open
space of the separate plate in the control valve body component.
• Do not pinch the coupler component between the separate plate and the control valve body
component.
acxuuw00000597
acxuuw00000598
acxuuw00000594
05-17–42
1871-1U-06B(05-17).fm 43 ページ 2006年3月15日 水曜日 午前11時20分
Tightening torque
5
8— 12 N·m {82— 122 kgf·cm, 72— 105 in·lbf}
3 6
7
8
acxuuw00000599
05-17
acxuuw00000592
Caution
• If the control valve body cover is installed with the wiring harnesses overlapped, the wiring
harnesses may be pinched between the cover and valve body causing the wiring harnesses to be
damaged. Therefore, verify that the wiring harnesses are not overlapped when installing the
control valve body cover.
NO GOOD GOOD
acxuuw00000600
05-17–43
1871-1U-06B(05-17).fm 44 ページ 2006年3月15日 水曜日 午前11時20分
Tightening torque
8— 12 N·m {82— 122 kgf·cm, 72— 105 in·lbf}
acxuuw00000601
acxuuw00000589
Note
• Completely remove oil with white gasoline or
similar.
11. Clean oil off the contact surface of the new control
valve body cover with the transaxle case.
acxuuw00000602
05-17–44
1871-1U-06B(05-17).fm 45 ページ 2006年3月15日 水曜日 午前11時20分
Caution
• Be careful that the coupler component
will not become caught between the
control valve body cover and transaxle
case.
acxuuw00000603
13. Install the new control valve body cover with new
seal bolts.
Tightening torque
9.8— 15.7 N·m {100— 160 kgf·cm, 87— 138
in·lbf} 05-17
id051723800800
1. Remove the transaxle. (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION[AW6A-EL,
AW6AX-EL].)
Caution
• The oil seal is easily damaged by the sharp edges of the torque converter splines. Do not let the
splines contact the oil seal.
• Do not drop the torque converter.
• Do not pinch fingers.
Caution
• Do not to damage the bushing on the oil pump body.
05-17–45
1871-1U-06B(05-17).fm 46 ページ 2006年3月15日 水曜日 午前11時20分
acxuuw00000605
INSTALLATION[AW6A-EL, AW6AX-EL].)
7. Install the transaxle. (See 05-17-29 AUTOMATIC
acxuuw00000606
TRANSAXLE REMOVAL/INSTALLATION[AW6A-
EL, AW6AX-EL].)
8. Perform the mechanical system test. (See 05-17-3 MECHANICAL SYSTEM TEST[AW6A-EL, AW6AX-EL].)
End Of Sie
TORQUE CONVERTER REMOVAL/INSTALLATION[AW6A-EL, AW6AX-EL]
id051723800700
1. Remove the transaxle. (See 05-17-29 AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION[AW6A-EL,
AW6AX-EL].)
Caution
• The oil seal is easily damaged by the sharp edges of the torque converter splines. Do not let the
splines contact the oil seal.
• Do not drop the torque converter.
• Do not pinch fingers.
ampjjw00002212
05-17–46
1871-1U-06B(05-17).fm 47 ページ 2006年3月15日 水曜日 午前11時20分
id051723801500
05-17
Note
• If the automatic transaxle is replaced, flush and inspect the oil cooler.
• When replacing the automatic transaxle, inspect the oil cooler together with flushing it using the following
procedure, and with the oil cooler hose removed.
acxuuw00000607
05-17–47
1871-1U-06B(05-17).fm 48 ページ 2006年3月15日 水曜日 午前11時20分
19.6—29.4
{2.00—2.99,
D 14.5—21.6}
6
19.6—29.4
{2.00—2.99, C
14.5—21.6}
R 4 5
4 R
1 7.8—10.8 N·m
R 2 {80—110 kgf·cm,
1 70—95 in·lbf}
R 2
R
1 R 2
2 C
1
3 2 R
8 1
7.8—10.8 N·m A
{80—110 kgf·cm, 3
70—95 in·lbf}
R D B
R 2 2
R
7 B
1 A RESONANCE
CHAMBER
2 R
R 2
5
N·m {kgf·m, ft·lbf}
18.6—25.5 {1.90—2.60, 13.8—18.8}
acxuuw00000608
05-17–48
1871-1U-06B(05-17).fm 49 ページ 2006年3月15日 水曜日 午前11時20分
Note
• Flushing must be performed after installation of an overhauled or replaced transaxle.
05-17
acxuuw00000609
2. Align the marks, and slide the oil hose onto the oil
pipe until it is fully seated as shown in the figure.
MARK
Note OIL PIPE
• If reusing the hose, install the new hose
clamp exactly on the mark left by the
previous hose camp.
acxuuw00000610
MARK
OIL PIPE
OIL HOSE 45 ° 90 °
HOSE CLAMP C
MARK MARK
70 ° 70 °
acxuuw00002342
05-17–49
1871-1U-06B(05-17).fm 50 ページ 2006年3月15日 水曜日 午前11時20分
R 3
4 R
5
2 1.8—2.2
{19—22, 16—19}
1
acxuuw00002296
05-17–50
1871-1U-06B(05-17).fm 51 ページ 2006年3月15日 水曜日 午前11時20分
Note
• Do not open more tabs than necessary for HEADER TAB
tank removal. HEIGHT
O-RING
acxuuw00002297
Note
• If any header tabs are missing from the core,
replace the radiator.
Note
• Step 3 will set jaw opening to the correct
specification.
acxuuw00002299
DRILL BIT
acxuuw00002300
05-17–51
1871-1U-06B(05-17).fm 52 ページ 2006年3月15日 水曜日 午前11時20分
LOCKING TYPE
PLIERS
6 7
2
3 4
1
8 5
acxuuw00002301
HEADER TAB
HEIGHT
O-RING
acxuuw00002297
05-17–52
1871-1U-06B(05-17).fm 53 ページ 2006年3月15日 水曜日 午前11時20分
1
3 6
5
4
2
49 E011 1A0
acxuuw00000612
05-17–53
1871-1U-06B(05-18).fm 1 ページ 2006年3月15日 水曜日 午前11時23分
End of Toc
AUTOMATIC TRANSAXLE SHIFT MECHANISM LOCATION INDEX
WM: AUTOMATIC TRANSAXLE
id051800801000
05-18
acxuuw00000399
End Of Sie
WM: SHIFT LOCK SYSTEM
05-18–1
1871-1U-06B(05-18).fm 2 ページ 2006年3月15日 水曜日 午前11時23分
id051800800100
1. Verify that the ignition key cannot be pulled out except in the P position.
• If there is any malfunction, inspect the interlock cable. (See 05-18-2 INTERLOCK CABLE INSPECTION.)
End Of Sie
INTERLOCK CABLE INSPECTION
id051800800200
1. Turn the ignition switch to the ON position. (Engine off)
2. Remove the clip of the selector lever base plate,
then remove the interlock cable from the U-
groove.
3. Remove the interlock cable from the selector
lever.
INTERLOCK
CABLE
CLIP
acxuuw00000400
acxuuw00000401
INTERLOCK CABLE
UNLOCK LOCK
acxuuw00000402
05-18–2
1871-1U-06B(05-18).fm 3 ページ 2006年3月15日 水曜日 午前11時23分
CLIP
acxuuw00000403
LOCK UNIT
05-18
BRACKET
acxuuw00000404
acxuuw00000405
INTERLOCK CABLE
acxuuw00000406
05-18–3
1871-1U-06B(05-18).fm 4 ページ 2006年3月15日 水曜日 午前11時23分
A B BRAKE SWITCH
SLIDER PIN
acxuuw00000407
INTERLOCK CABLE
acxuuw00000408
Caution
• Do not connect the brake switch
connector until the interlock cable
acxuuw00000407
adjustment is completed.
14. Install the lock unit to the bracket. (See05-18-10 Interlock Cable Installation Note.)
15. Rotate the slider pin to release the lock and verify that it slides freely.
16. Verify that the slider pin contacts the brake pedal
stopper rubber and rotate the slider pin to lock.
UNLOCK
LOCK
acxuuw00000409
05-18–4
1871-1U-06B(05-18).fm 5 ページ 2006年3月15日 水曜日 午前11時23分
CLIP
acxuuw00000403
INTERLOCK CABLE
UNLOCK LOCK
acxuuw00000410
05-18–5
1871-1U-06B(05-18).fm 6 ページ 2006年3月15日 水曜日 午前11時23分
OPERATION WHEN
BRAKE PEDAL IS
RELEASED
acxuuw00000411
acxuuw00000412
End Of Sie
05-18–6
1871-1U-06B(05-18).fm 7 ページ 2006年3月15日 水曜日 午前11時23分
acxuuw00000413
acxuuw00000414
05-18–7
1871-1U-06B(05-18).fm 8 ページ 2006年3月15日 水曜日 午前11時23分
5
3
7
4 9
6
A A
acxuuw00000415
05-18–8
1871-1U-06B(05-18).fm 9 ページ 2006年3月15日 水曜日 午前11時23分
TCM SELECTOR
CABLE
MANUAL
SHAFT
LEVER
acxuuw00000416
acxuuw00002399
acxuuw00002400
acxuuw00000419
05-18–9
1871-1U-06B(05-18).fm 10 ページ 2006年3月15日 水曜日 午前11時23分
Caution
• Bending the selector cable in the manner DO NOT BEND
shown in the figure will damage the cable
and it may become loose when shifted.
When installing the selector cable, hold it
straight.
acxuuw00000432
5. Install the clip as shown in the figure.
CLIP
acxuuw00000433
Note CLIP
• Install the selector lever to the manual shaft UPWARD
lever with the clip side of the selector cable
end facing up.
INTERLOCK CABLE
acxuuw00000423
2. Verify that the marking on the slider pin is
positioned as shown in the figure.
LOCK UNIT
BRACKET
acxuuw00000424
05-18–10
1871-1U-06B(05-18).fm 11 ページ 2006年3月15日 水曜日 午前11時23分
A B BRAKE SWITCH
SLIDER PIN
acxuuw00000425
4. Fully pull the end of the interlock cable.
INTERLOCK CABLE
05-18
acxuuw00000426
5. Push the a 1.5mm {0.059 in} round bar or similar
into hole B and hole C of the lock unit until it LOCK UNIT INTERLOCK
passes through. CABLE
C
6. Disconnect the brake switch connector.
7. Remove the brake switch. (See 04-11-6 BRAKE A B BRAKE SWITCH
PEDAL REMOVAL/INSTALLATION.) SLIDER PIN
8. Install a new brake switch. (See 04-11-6 BRAKE
PEDAL REMOVAL/INSTALLATION.)
Caution
• Do not connect the brake switch
connector until the interlock cable is
acxuuw00000425
installed.
Caution
• Allowing the interlock cable to be bent or BRACKET
twisted during installation can affect the
lock unit operation.
LOCK UNIT
10. Rotate the slider pin to release the lock and verify
that it slides freely.
acxuuw00000427
11. Pull the slider pin outward until it contacts the
brake pedal stopper rubber and rotate the slider
pin to lock.
12. Verify that the selector lever in the P position. UNLOCK
LOCK
acxuuw00000428
05-18–11
1871-1U-06B(05-18).fm 12 ページ 2006年3月15日 水曜日 午前11時23分
CLIP
acxuuw00000429
INTERLOCK CABLE
UNLOCK LOCK
acxuuw00000430
CONVEX PART
CLIP
acxuuw00001380
05-18–12
1871-1U-06B(05-50).fm 1 ページ 2006年3月15日 水曜日 午前11時24分
TECHNICAL DATA
05-50 TECHNICAL DATA
TRANSMISSION/TRANSAXLE
TECHNICAL DATA . . . . . . . . . . . . . . . . 05-50–1
End of Toc
TRANSMISSION/TRANSAXLE TECHNICAL DATA
WM: TRANSMISSION/TRANSAXLE
id055000800100
Item Specification
N position → D range: 1.5 s or less
Average time lag
N position → R position: 1.5 s or less
Type: JWS3309
ATF
Capacity (Approx. quantity): 7.0 L {7.4 US qt, 6.2 lmp qt}
Distance A ((between the end of the torque converter
31.4 mm {1.24 in}
and the end of the converter housing))
VSS
Signal Current (mA)
High 12.0—16.0
Low 4.0—8.0
End Of Sie
05-50–1
1871-1U-06B(05-60).fm 1 ページ 2006年3月15日 水曜日 午前11時24分
SERVICE TOOLS
05-60 SERVICE TOOLS
TRANSMISSION/TRANSAXLE SST. . . . 05-60–1
End of Toc
TRANSMISSION/TRANSAXLE SST
AT: TRANSMISSION/TRANSAXLE
id056000500100
1: Mazda SST number
2: Global SST number
Example
1:49 UN30 3009
2:303-009
Crankshaft
damper
remover
05-60
* : The SST (49 E017 5A0) can be used in place of the SST (49 C017 5A0).
End Of Sie
05-60–1
1871-1U-06B(06-10).fm 1 ページ 2006年3月15日 水曜日 午前11時25分
STEERING 06
SECTION
End of Toc
GENERAL PROCEDURES (STEERING)
WM: STEERING
id061000800100
Wheel and Tire Installation
1. When installing the wheels and tires, tighten the
wheel nuts in a criss-cross pattern to the following
tightening torque.
Tightening torque 1
88.2— 117.6 N·m {9.00— 11.99 kgf·m, 4 3
65.06— 86.73 ft·lbf}
2 5
acxuuw00001552
Connector Disconnection
1. Disconnect the negative battery cable before performing any work that requires handling of connectors. (See
01-17-2 BATTERY REMOVAL/INSTALLATION[L3 WITH TC])
Note
• Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools
are in designated position.
End Of Sie
06-10–1
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
POWER STEERING
06-14 POWER STEERING
STEERING LOCATION INDEX . . . . . . . . 06-14–2 Mounting Rubber Disassembly Note. . . 06-14–13
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . 06-14–3 STEERING GEAR AND LINKAGE
POWER STEERING FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . 06-14–13
INSPECTION . . . . . . . . . . . . . . . . . . . . 06-14–3 Steering Rack Inspection . . . . . . . . . . . 06-14–13
Fluid Level Inspection . . . . . . . . . . . . . 06-14–3 Tie-rod End Inspection . . . . . . . . . . . . . 06-14–14
Fluid Leakage Inspection . . . . . . . . . . . 06-14–3 Tie rod Inspection . . . . . . . . . . . . . . . . . 06-14–14
Fluid Pressure Inspection . . . . . . . . . . 06-14–4 STEERING GEAR AND LINKAGE
STEERING WHEEL AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 06-14–14
COLUMN INSPECTION . . . . . . . . . . . . 06-14–5 Mounting Rubber Assembly Note . . . . . 06-14–16
Steering Wheel Play Inspection . . . . . . 06-14–5 Oil Seal Assembly Note . . . . . . . . . . . . 06-14–17
Steering Wheel Looseness Steering Rack Assembly Note. . . . . . . . 06-14–17
Inspection . . . . . . . . . . . . . . . . . . . . . 06-14–5 Stopper Assembly Note . . . . . . . . . . . . 06-14–18
Steering Wheel Effort Inspection . . . . . 06-14–5 Oil seal (Upper side)
STEERING WHEEL AND Assembly Note . . . . . . . . . . . . . . . . . 06-14–18
COLUMN Bearing (upper side)
REMOVAL/INSTALLATION . . . . . . . . . 06-14–6 Assembly Note . . . . . . . . . . . . . . . . . . 06-14–18
Steering Wheel Removal Note. . . . . . . 06-14–7 Oil Seal (lower side) Assembly Note . . . 06-14–19
Steering Lock Mounting Bolts Pinion Shaft Assembly Note . . . . . . . . . 06-14–19
Removal Note . . . . . . . . . . . . . . . . . . 06-14–7 Housing Cover Assembly Note . . . . . . . 06-14–19 06-14
Key Cylinder (Without Advanced Dust cover Assembly Note . . . . . . . . . . 06-14–19
Keyless System) Removal Note. . . . . 06-14–7 Adjusting Cover, Locknut
Steering Lock Mounting Bolts (Adjusting Cover) Assembly Note . . . . 06-14–19
Installation Note . . . . . . . . . . . . . . . . . 06-14–7 Tie-rod Assembly Note . . . . . . . . . . . . . 06-14–20
Steering Shaft Installation Note . . . . . . 06-14–8 Boot Assembly Note . . . . . . . . . . . . . . . 06-14–21
Steering Wheel Installation Note . . . . . 06-14–8 POWER STEERING OIL PUMP
STEERING SHAFT INSPECTION. . . . . . 06-14–8 REMOVAL/INSTALLATION . . . . . . . . . . 06-14–21
STEERING GEAR AND LINKAGE POWER STEERING OIL PUMP
REMOVAL/INSTALLATION. . . . . . . . . . 06-14–9 DISASSEMBLY/ASSEMBLY . . . . . . . . . 06-14–22
STEERING GEAR AND LINKAGE Power Steering Oil Pump Component
DISASSEMBLY . . . . . . . . . . . . . . . . . . . 06-14–10 Disassembly Note . . . . . . . . . . . . . . . 06-14–23
Tie-rod End Disassembly Note . . . . . . 06-14–11 Clip Disassembly Note . . . . . . . . . . . . . 06-14–23
Tie-rod Disassembly Note . . . . . . . . . . 06-14–11 Shaft Component
Locknut (Adjusting Cover), Adjusting Disassembly Note . . . . . . . . . . . . . . . 06-14–24
Cover Disassembly Note . . . . . . . . . . 06-14–12 Oil seal Disassembly Note . . . . . . . . . . 06-14–24
Pinion Shaft, Oil seal (lower side) Oil seal Assembly Note . . . . . . . . . . . . . 06-14–24
Disassembly Note . . . . . . . . . . . . . . . 06-14–12 Side plate Assembly Note . . . . . . . . . . . 06-14–24
Bearing (upper side), Oil seal Rotor Assembly Note . . . . . . . . . . . . . . 06-14–25
(upper side) Disassembly Note . . . . . 06-14–12 Cam Ring Assembly Note . . . . . . . . . . . 06-14–25
Clip Disassembly Note . . . . . . . . . . . . . 06-14–13 Rear Pump Body Assembly Note . . . . . 06-14–25
Oil Seal Disassembly Note. . . . . . . . . . 06-14–13 Clip Assembly Note . . . . . . . . . . . . . . . . 06-14–25
End of Toc
WM: STEERING
06-14–1
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
POWER STEERING
STEERING LOCATION INDEX
id061400800100
4 AWD
(Mexico spec.)
5
1
acxuuw00002580
AIR BLEEDING
id061400800200
Caution
• Do not turn the steering wheel during the fluid level inspection, otherwise the fluid level changes
and cannot be inspected correctly.
1. Inspect the fluid level. (See 06-14-3 POWER STEERING FLUID INSPECTION.)
2. Jack up the front of the vehicle and support it on safety stands.
3. Turn the steering wheel fully to the left and right several times with the engine not running.
4. Reinspect the fluid level.
• If it has dropped, add fluid.
5. Repeat Steps 3 and 4 until the fluid level stabilizes.
6. Lower the vehicle.
7. Start the engine and let it idle.
8. Turn the steering wheel fully to the left and right several times.
9. Verify that the fluid is not foamy and that the fluid level has not dropped.
• If the fluid level has dropped, add fluid as necessary and repeat Steps 8 and 9.
End Of Sie
POWER STEERING FLUID INSPECTION
WM: POWER STEERING FLUID
id061400800500
Fluid Level Inspection 06-14
1. Inspect the power steering fluid level.
• Add fluid to the specified level as necessary.
Caution
• If the steering wheel is kept in the fully turned position for more than 5, the fluid temperature will
rise excessively and adversely affect the oil pump.
Note
• The points where fluid leakage may occur
are indicated in the figure.
acxuuw00002581
49 H002 671
acxuuw00000504
Tightening torque
29.4— 44.1 N·m {3.0— 4.4 kgf·m, 22— 32
ft·lbf} 49 G032 3A4A
Caution
• If the valve is left closed for more than 5,
the fluid temperature will rise excessively
and adversely affect the oil pump.
acxuuw00000506
Oil pump fluid pressure
10.31— 10.80 MPa {105.2— 110.1 kgf/cm2,
1,496— 1,566 psi}
Caution
• If the steering wheel is kept in the fully
turned position for more than 5 seconds,
acxuuw00000507
the fluid temperature will rise excessively
and adversely affect the oil pump.
06-14–4
1871-1U-06B(06-14).fm 5 ページ 2006年3月15日 水曜日 午前11時25分
POWER STEERING
10. Remove the SSTs. Install and tighten the pressure pipe to the specified torque.
Tightening torque
29.4— 44.1 N·m {3.0— 4.4 kgf·m, 22— 32 ft·lbf}
id061400800300
Steering Wheel Play Inspection
1. With the wheels in the straight-ahead position, gently turn the steering wheel to the left and right and verify that
the play is within the specification.
• If the play exceeds the specification, either the steering joints are worn or the backlash of the steering gear
is excessive. Correct as necessary.
acxuuw00002353
Warning
• Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read AIR BAG SYSTEM WARNINGS before handling the air bag module. (See
08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-10-5 AIR BAG SYSTEM SERVICE
CAUTIONS.)
4. Start the engine and warm the power steering fluid to 50— 60 °C {122— 140 °F}.
5. Measure the steering wheel effort using a torque
wrench.
• If not within the specification, verify the
following:
— No air in steering system
— No fluid leakage at hose or connectors
— Function of oil pump and steering gear
Note
• To determine whether the steering effort is
acxuuw00002354
06-14–5
1871-1U-06B(06-14).fm 6 ページ 2006年3月15日 水曜日 午前11時25分
POWER STEERING
End Of Sie
Warning
• Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read AIR BAG SYSTEM WARNINGS before handling the air bag module. (See
08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-10-5 AIR BAG SYSTEM SERVICE
CAUTIONS.)
1
3
2 39.2—49.0
{4.0—4.9, 30—36}
R
8.8—12.8 N·m
{89.8—130.5 kgf·cm, 77.8—113.2 in·lbf}
4
10
R
5 7
6
8
9
15.7—22.5
{1.7—2.2,
11.6—16.5} 13
11
18.6—26.5
{1.9—2.7,
14—19}
12
N·m {kgf·m, ft·lbf}
acxuuw00000494
06-14–6
1871-1U-06B(06-14).fm 7 ページ 2006年3月15日 水曜日 午前11時25分
POWER STEERING
7 Joint cover 11 Steering lock component
8 Steering shaft 12 Ignition switch
(See 06-14-8 Steering Shaft Installation Note.) (See 09-21-2 IGNITION SWITCH REMOVAL/
9 Dust cover INSTALLATION.)
10 Steering lock mounting bolts 13 Key cylinder (Without advanced keyless system)
(See 06-14-7 Steering Lock Mounting Bolts (See06-14-7 Key Cylinder (Without Advanced
Removal Note.) Keyless System) Removal Note.)
(See 06-14-7 Steering Lock Mounting Bolts
Installation Note.)
Caution
• Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will
collapse.
acxuuw00000495
PIN
acxuuw00001910
acxuuw00000496
06-14–7
1871-1U-06B(06-14).fm 8 ページ 2006年3月15日 水曜日 午前11時25分
POWER STEERING
Steering Shaft Installation Note
Caution
• Do not apply a shock in the axial direction of the shaft.
B
C
acxuuw00000497
id061400800600
1. Inspect the following.
(1) Column bearing for damage
(2) Steering shaft length
• Replace the steering shaft component as
necessary.
E6U612ZW7013
B6U0612W008
06-14–8
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
POWER STEERING
STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION
id061400800900
Caution
• Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing
the following procedures, disconnect the ABS wheel-speed sensor connector (axle side) and fix
the wiring harness to an appropriate place where it will not be pulled by mistake while servicing
the vehicle.
7.8—10.8
{0.80—1.10, 06-14
5.76— 7.96}
74.4—104.8
{7.59— 10.6,
54.9—77.2, } 1
74.4—104.8
{7.59— 10.6,
54.9—77.2, }
acxuuw00001950
06-14–9
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
POWER STEERING
End Of Sie
Caution
• Place copper plates, rag, or similar material in a vise, when securing the mounting bracket portion
of the steering gear.
17
SST SST 21 15
28 SST
SST 27 2
20
18
19
28
SST
9 SST
29 10
12 11
14
13
3
28
4 8
SST
5 SST
7 6
6 7
5
8
4
22 3
24
26
25 23
acxuuw00002543
06-14
MARK
acxuuw00000654
acxuuw00000952
49 H032 351
acxuuw00001725
Caution
• If a tool such as a torque wrench is 49 E032 308
installed to the SST (49 E032 308), install
the tool so that it is perpendicular to the
SST as shown in the figure. If the tool is
not installed as instructed, the SST can
separate from the locknut easily which NUT
could cause damage to the locknut while
doing the work. BOLT
3. Using the bolt/nut produced in Step 1, remove the ACROSS FLAT 24 mm {0.94 in}
adjusting cover. acxuuw00002547
acxuuw00000953
49 B032 301
acxuuw00001156
END OF
THE CLIP
RACK STOPPER
acxuuw00001605
49 N032 319A
acxuuw00000954
acxuuw00000955
acxuuw00001775
06-14–13
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
POWER STEERING
Tie-rod End Inspection
1. Inspect the tie-rod end for damage and boot cracks. Replace it if necessary.
2. Inspect the ball joint for looseness. Replace the tie-rod end if necessary.
3. Rotate the ball joint five times.
4. Measure the rotation torque of the ball joint using
the SST and a pull scale.
Rotation torque
0.5— 3.0 N·m {0.06— 30 kgf·cm, 5— 26 in·lbf}
Pull scale reading
49 0180 510B
5— 30 N {0.6— 3.0 kgf, 3.7— 22 lbf}
acxuuw00001780
End Of Sie
acxuuw00001777
Caution
• Place copper plates, rag, or similar material in a vise, when securing the mounting bracket portion
of the steering gear.
06-14–14
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
POWER STEERING
1. Assemble in the order indicated in the table. .
28 10—16 N·m
{1.0—1.5 kgf·cm, 0.9—1.3 in·lbf}
10—16 N·m
{1.0—1.5 kgf·cm,
0.9—1.3 in·lbf}
17
GREASE
16
R
20—29 {2.1—2.9, 15—21}
SST SST 9
2 SST 10 13
SST
R 29 24—29 {2.5—2.9, 18—21}
3 SST
SST
11
2 12
1 20 SST
18 19 06-14
27 20—29
69—98 {7.1—9.9, 51—72}
14
25 {2.1—2.9, SST
15—21}
SEALANT
15 SILICON
GREASE
68.6—98.0 26 49—69 2 GREASE
{7.00—9.99, {5.0—7.0,
22
SST
50.6—72.2} 37—50}
23 24
R 23
24
SILICON
GREASE
R
GREASE 22 25 26
27
68.6—98.0
8
7 {7.00—9.99,
5 50.6—72.2}
69—98
R
6 4
{7.1—9.9,
51—72} R
MOLYBDENUM
GREASE
GREASE
N·m {kgf·m, ft·lbf}
acxuuw00000995
13.6 mm 13.6 mm
{0.53 in} {0.53 in}
acxuuw00002360
49 B032 317
49 B018 003
acxuuw00000996
POWER STEERING
4. Reverse the gear housing, then press the
mounting rubber until the mounting rubber end MOUNTING RUBBER
comes out completely from the other side. At this
time, make sure that the mounting rubber and
steel pipe are aligned.
49 B032 317
STEEL PIPE
49 B018 003
49 B032 317
49 B018 003
06-14
acxuuw00000997
49 H032 326
49 N032 319A
acxuuw00000998
PLASTIC BAG
acxuuw00000999
06-14–17
1871-1U-06B(06-14).fm 18 ページ 2006年3月15日 水曜日 午前11時25分
POWER STEERING
Stopper Assembly Note
1. Using an appropriate pipe and a hammer, insert
the rack stopper into the gear housing until the
clip installation groove of the gear housing comes
out.
acxuuw00001000
49 G032 3A1
acxuuw00001001
49 H032 334
acxuuw00001002
acxuuw00001003
06-14–18
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
POWER STEERING
Oil Seal (lower side) Assembly Note
1. Assemble the oil seal (lower side) using the SST.
Substitution SST
• 49 L032 312A
Outer diameter: 35— 36 mm {1.2— 1.3 in}
Cylindrical shape outer diameter of 40 mm 49 L032 312A
{1.6 in} or more.
acxuuw00001007
06-14
acxuuw00001006
Specified grease
• Rubber grease (Mazda genuine parts) or
equivalent.
acxuuw00002261
acxuuw00002544
49 D032 316
acxuuw00001008
Caution
• If a tool such as a torque wrench is
installed to the SST (49 E032 308), install
the tool so that it is perpendicular to the 49 E032 308
SST as shown in the figure. If the tool is
not installed as instructed, the SST can
separate from the locknut easily which
could cause damage to the locknut while
doing the work. NUT 49 E032 308
Note BOLT
• Be sure that the adjusting cover will not turn
together with the locknut. ACROSS FLAT 24 mm {0.94 in}
acxuuw00002548
acxuuw00002345
acxuuw00001725
POWER STEERING
2. Lock the steering rack end against rotation with a
suitable wrench and install the other side tie rod 49 H032 351
using the SST.
Substitution SST
• 49 H032 351 SUITABLE WRENCH
Width across flats 34mm {1.3 in} (Torque
control enabled wrench)
acxuuw00002262
id061400800700
1. Remove the drive belt. (See 01-10-3 DRIVE BELT REMOVAL/INSTALLATION[L3 WITH TC].)
06-14
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
29.4—44.1
1 {3.00—4.49, 21.7—32.5}
2
4
18.6—25.5
{1.9—2.6, 14—18}
18.6—25.5
{1.9—2.6, 14—18} 3
N·m {kgf·m, ft·lbf}
acxuuw00001346
End Of Sie
06-14–21
1871-1U-06B(06-14).fm 22 ページ 2006年3月15日 水曜日 午前11時25分
POWER STEERING
POWER STEERING OIL PUMP DISASSEMBLY/ASSEMBLY
id061400800800
Note
• The following procedure is for replacement of the O-ring and oil seal only. Replace the pump component if
other repairs are necessary.
25.4—29.4
{2.60—2.99, 18.8—21.6} 49—69 {5.0—7.0, 36.2—50.8} 22—26 {2.3—2.6, 16.3—19.1}
ATF R
4 R ATF
6
2
10
13 11
14 12 R
1
R ATF
SST
16 15
17
R ATF
7
R
19 R 8
20
SST
18 9
R ATF
acxuuw00001915
06-14–22
1871-1U-06B(06-14).fm 23 ページ 2006年3月15日 水曜日 午前11時25分
POWER STEERING
13 Cam ring 18 Shaft component
(See 06-14-25 Cam Ring Assembly Note.) (See 06-14-24 Shaft Component Disassembly
14 Rotor Note.)
(See 06-14-25 Rotor Assembly Note.) 19 Oil seal
15 Vane (See 06-14-24 Oil seal Disassembly Note.)
(See 06-14-24 Oil seal Assembly Note.)
16 Side plate
(See 06-14-24 Side plate Assembly Note.) 20 Front pump body
17 O-rings
Caution
49 F032 301
• Use the SST to prevent damage to the
pump when securing it in a vise.
06-14
acxuuw00002389
CLIP R
acxuuw00001917
06-14–23
1871-1U-06B(06-14).fm 24 ページ 2006年3月15日 水曜日 午前11時25分
POWER STEERING
Shaft Component Disassembly Note
1. Tap out the shaft component from the front pump
body using a plastic hammer.
acxuuw00002347
acxuuw00002348
acxuuw00001919
acxuuw00002349
06-14–24
1871-1U-06B(06-14).fm 25 ページ 2006年3月15日 水曜日 午前11時25分
POWER STEERING
Rotor Assembly Note
1. Install to the front pump body so that area B of the
groove is on the rear pump body side as shown in SEC. A-A
the figure. REAR PUMP BODY SIDE
AREA B
A A
acxuuw00002350
06-14
acxuuw00001921
CLIP R
acxuuw00001918
06-14–25
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
TECHNICAL DATA
06-50 TECHNICAL DATA
STEERING TECHNICAL DATA. . . . . . . . 06-50–1
End of Toc
STEERING TECHNICAL DATA
WM: STEERING
id065000800200
Item Specification
Power steering fluid type ATF M-III, M-V or equivalent (e.g. Dexron®II)
2WD, AWD (except Mexico spec.): 0.89 L {0.94 US qt, 0.78 lmp qt}
Power steering fluid capacity (approx. quantity)
AWD (Mexico spec.): 0.98 L {1.0 US qt, 0.86 lmp qt}
Oil pump fluid pressure 10.31—10.80 MPa {105.2—110.1 kgf/cm2, 1,496—1,566 psi}
Gear housing fluid pressure 10.31—10.80 MPa {105.2—110.1 kgf/cm2, 1,496—1,566 psi}
Steering wheel play 0—30 mm {0—1.18 in}
Steering wheel effort (reference value) 7.8 N·m {80 kgf·cm, 69 in·lbf} max.
Steering shaft length 211.6 mm {8.3 in}
Large diameter portion (near point A): 0.15 mm {0.006 in} max.
Steering rack runout
Small diameter portion (near point B): 0.20 mm {0.008 in} max. 06-50
0.5—3.0 N·m {0.06—30 kgf·cm, 5—26 in·lbf}
Tie-rod end ball joint Rotation torque
[Pull scale reading 5—30 N {0.6—3.0 kgf, 3.7—22 lbf}]
0.4—4.0 N·m {5—40 kgf·cm, 4—35 in·lbf}
Tie rod ball joint swing torque
[Pull scale reading 4.2—41.6 N {0.43—4.24 kgf, 0.95—9.35 lbf}]
End Of Sie
SERVICE TOOLS
06-60 SERVICE TOOLS
STEERING SST. . . . . . . . . . . . . . . . . . . . 06-60–1
End of Toc
STEERING SST
WM: STEERING
id066000800100
49 E032 308
Wrench — —
End Of Sie
06-60–1
1871-1U-06B(07-02).fm 1 ページ 2006年3月16日 木曜日 午後4時22分
Toc of SCT
ON-BOARD DIAGNOSTIC . . . . 07-02 BASIC SYSTEM . . . . . . . . . . . . 07-11
SYMPTOM CONTROL SYSTEM . . . . . . . . 07-40
TROUBLESHOOTING . . . . . . 07-03 TECHNICAL DATA . . . . . . . . . . 07-50
REFRIGERANT SYSTEM . . . . . 07-10 SERVICE TOOLS . . . . . . . . . . . 07-60
Toc of SCT
07-02 ON-BOARD DIAGNOSTIC
HVAC SYSTEM WIRING DIAGRAM . . . . 07-02–2 DTC B2832 . . . . . . . . . . . . . . . . . . . . . . . 07-02–9
DTC B1251, B1253. . . . . . . . . . . . . . . . . . 07-02–3 DTC B2834 . . . . . . . . . . . . . . . . . . . . . . . 07-02–10
DTC B1251, B1253, B1255, B1257, A/C OPERATION CHECK MODE . . . . . . 07-02–10
B1274, B1275, B1282, B1283, B1947, A/C OPERATION CHECK MODE
B2014 (MULTIPLE DTCS DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . 07-02–11 07-02
INDICATED). . . . . . . . . . . . . . . . . . . . . . 07-02–4 DTC DISPLAY . . . . . . . . . . . . . . . . . . . . . 07-02–11
DTC B1260, B1261. . . . . . . . . . . . . . . . . . 07-02–4 CLEARING DTC . . . . . . . . . . . . . . . . . . . 07-02–11
DTC B1255, B1257. . . . . . . . . . . . . . . . . . 07-02–5 DTC TABLE . . . . . . . . . . . . . . . . . . . . . . . 07-02–12
DTC B1260, B1261, B1274, B1275, PID/DATA MONITOR DISPLAY . . . . . . . . 07-02–13
B1282, B1283 (MULTIPLE DTCS PID/DATA MONITOR TABLE. . . . . . . . . . 07-02–13
INDICATED) . . . . . . . . . . . . . . . . . . . . . . 07-02–6 ACTIVE COMMAND MODES
DTC B1274, B1275. . . . . . . . . . . . . . . . . . 07-02–7 DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . 07-02–13
DTC B1282, B1283. . . . . . . . . . . . . . . . . . 07-02–8 ACTIVE COMMAND MODES TABLE . . . 07-02–13
DTC B1947, B2014. . . . . . . . . . . . . . . . . . 07-02–8
End of Toc
WM: HEATER, VENTILATION AND AIR CONDITIONING (HVAC)
07-02–1
1871-1U-06B(07-02).fm 2 ページ 2006年3月16日 木曜日 午後4時22分
ON-BOARD DIAGNOSTIC
HVAC SYSTEM WIRING DIAGRAM
id070200800100
IG2 B+
A
INFORMATION 5V
DISPLAY REFRIGERANT
PRESSURE
SWITCH MAGNETIC
PASSENGER 5V CLUTCH
B COMPARTMENT
TEMPERATURE J
SENSOR N AIR MIX
H ACTUATOR
U M
EVAPORATOR
TEMPERATURE S
SENSOR
F
P
AMBIENT AIRFLOW MODE
TEMPERATURE ACTUATOR
Q M
SENSOR
O
L
B A
I AIR INTAKE
C
ACTUATOR
CPU K M
A
E
SOLAR RADIATION BLOWER MOTOR
SENSOR BLOWER RELAY
5V T M
acxuuw00002302
End Of Sie
07-02–2
1871-1U-06B(07-02).fm 3 ページ 2006年3月16日 木曜日 午後4時22分
ON-BOARD DIAGNOSTIC
DTC B1251, B1253
id070200800300
DTC B1251,
Passenger compartment temperature sensor system
B1253
• Passenger compartment temperature sensor malfunction
POSSIBLE
• Open or short circuit in wiring harness between climate control unit and passenger compartment
CAUSE
temperature sensor
Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect the passenger compartment temperature Yes Go to the next step.
sensor. (See 07-40-23 PASSENGER No Replace the passenger compartment temperature
COMPARTMENT TEMPERATURE SENSOR sensor. (See 07-40-23 PASSENGER COMPARTMENT
INSPECTION.) TEMPERATURE SENSOR REMOVAL/
• Is it normal? INSTALLATION.)
2 • Disconnect the climate control unit connector and Yes Repair the wiring harness.
the passenger compartment temperature sensor No Go to the next step.
connector.
• Is there an open circuit in the wiring harness
between the following terminals of the climate
control unit and the passenger compartment
temperature sensor?
— H— B
— C— A 07-02
3 • Is there a short circuit to ground in the wiring Yes Repair the wiring harness.
harness between climate control unit terminal H No Connect the climate control unit connector, then go to
and passenger compartment temperature sensor the next step.
terminal B?
4 • Turn the ignition switch to the ON position. Yes The system is normal at present. (Clear the malfunction
• Inspect the voltage at the following climate control from the memory.)
unit terminal (wiring harness-side). No Inspect the connection of the climate control unit
— Terminal H (passenger compartment connector. (See 07-40-13 CLIMATE CONTROL UNIT
temperature sensor input signal) INSPECTION [FULL-AUTO AIR CONDITIONER].)
• Is the voltage normal? (Approx. 5 V)
End Of Sie
07-02–3
1871-1U-06B(07-02).fm 4 ページ 2006年3月16日 木曜日 午後4時22分
ON-BOARD DIAGNOSTIC
DTC B1251, B1253, B1255, B1257, B1274, B1275, B1282, B1283, B1947, B2014 (MULTIPLE DTCS
INDICATED)
id070200800400
DTC B1251,
B1253, B1255,
B1257, B1947,
Climate control unit (+5 V power supply or sensor ground) system
B2014, B1282,
B1283, B1274,
B1275
POSSIBLE • Open circuit in wiring harnesses between climate control unit and each temperature sensor, air mix
CAUSE actuator, or airflow mode actuator
Diagnostic Procedure
STEP INSPECTION ACTION
1 • Disconnect the climate control unit connector and Yes Repair the wiring harness.
the evaporator temperature sensor connector. No Inspect the connection of the climate control unit
• Is there an open circuit in the wiring harness connector.
between climate control unit terminal C and
evaporator temperature sensor terminal A?
CLIMATE CONTROL UNIT CONNECTOR
EVAPORATOR TEMPERATURE SENSOR CONNECTOR
W U S Q O M K I G E C A
B A
X V T R P N L J H F D B
End Of Sie
DTC B1260, B1261 id070200800500
DTC B1260,
Solar radiation sensor system
B1261
POSSIBLE • Solar radiation sensor malfunction
CAUSE • Open or short circuit in wiring harness between climate control unit and solar radiation sensor
Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect the solar radiation sensor. (See 07-40-23 Yes Go to the next step.
SOLAR RADIATION SENSOR INSPECTION.) No Replace the solar radiation sensor. (See 07-40-22
• Is it normal? SOLAR RADIATION SENSOR REMOVAL/
INSTALLATION.)
2 • Disconnect the climate control unit connector and Yes Go to the next step.
the solar radiation sensor connector. No Repair the wiring harness.
• Is there continuity between the following terminals
of the climate control unit and the solar radiation
sensor?
— E— B
— J— A
3 • Is there a short circuit to ground in the wiring Yes Repair the wiring harness.
harness between climate control unit terminal E No Inspect the connection of the climate control unit
and solar radiation sensor terminal B? connector. (See 07-40-13 CLIMATE CONTROL UNIT
INSPECTION [FULL-AUTO AIR CONDITIONER].)
CLIMATE CONTROL UNIT CONNECTOR SOLAR RADIATION SENSOR CONNECTOR
W U S Q O M K I G E C A
X V T R P N L J H F D B B A
End Of Sie
07-02–4
1871-1U-06B(07-02).fm 5 ページ 2006年3月16日 木曜日 午後4時22分
ON-BOARD DIAGNOSTIC
DTC B1255, B1257
id070200800600
DTC B1255,
Ambient temperature sensor system
B1257
POSSIBLE • Ambient temperature sensor malfunction
CAUSE • Open or short circuit in wiring harness between climate control unit and ambient temperature sensor
Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect the ambient temperature sensor. (See 07- Yes Go to the next step.
40-24 AMBIENT TEMPERATURE SENSOR No Replace the ambient temperature sensor. (See 07-40-
INSPECTION.) 24 AMBIENT TEMPERATURE SENSOR REMOVAL/
• Is it normal? INSTALLATION.)
2 • Disconnect the climate control unit connector and Yes Repair the wiring harness.
the ambient temperature sensor connector. No Go to the next step.
• Is there an open circuit in the wiring harness
between the following terminals of the climate
control unit and the ambient temperature sensor?
— L— B
— C— A
3 • Is there a short circuit to ground in the wiring Yes Repair the wiring harness.
harness between climate control unit terminal L No Connect the climate control unit connector, then go to
and ambient temperature sensor terminal B? the next step.
07-02
4 • Turn the ignition switch to the ON position. Yes The system is normal at present. (Clear the malfunction
• Inspect the voltage at the following climate control from the memory.)
unit terminal (wiring harness-side). No Inspect the connection of the climate control unit
— Terminal L (ambient temperature sensor input connector. (See 07-40-13 CLIMATE CONTROL UNIT
signal) INSPECTION [FULL-AUTO AIR CONDITIONER].)
• Is the voltage normal? (Approx. 5 V)
W U S Q O M K I G E C A
B A
X V T R P N L J H F D B
End Of Sie
07-02–5
1871-1U-06B(07-02).fm 6 ページ 2006年3月16日 木曜日 午後4時22分
ON-BOARD DIAGNOSTIC
DTC B1260, B1261, B1274, B1275, B1282, B1283 (MULTIPLE DTCS INDICATED)
id070200800700
DTC B1260,
B1261, B1282,
Climate control unit (+5 V power supply) system
B1283, B1274,
B1275
POSSIBLE • Open or short circuit in wiring harnesses between climate control unit and solar radiation sensor, air mix
CAUSE actuator, or airflow mode actuator
Diagnostic Procedure
STEP INSPECTION ACTION
1 • Disconnect the climate control unit connector and Yes Repair the wiring harness.
the airflow mode actuator connector. No Go to the next step.
• Is there an open circuit in the wiring harness
between climate control unit terminal J and airflow
mode actuator terminal B?
2 • Is there a short circuit to ground in the wiring Yes Repair the wiring harness.
harness between climate control unit terminal J No Go to the next step.
and airflow mode actuator terminal B?
3 • Is there a short circuit to ground in the wiring Yes Repair the wiring harness.
harness between climate control unit terminal J No Go to the next step.
and air mix actuator terminal A?
4 • Is there a short circuit to ground in the wiring Yes Repair the wiring harness.
harness between climate control unit terminal J No The system is normal at present. (Clear the malfunction
and solar radiation sensor terminal A? from the memory.)
CLIMATE CONTROL UNIT CONNECTOR AIR MIX ACTUATOR AIRFLOW MODE SOLAR RADIATION
CONNECTOR ACTUATOR CONNECTOR SENSOR CONNECTOR
W U S Q O M K I G E C A
X V T R P N L J H F D B F * D C B A F * D C B A B A
End Of Sie
07-02–6
1871-1U-06B(07-02).fm 7 ページ 2006年3月16日 木曜日 午後4時22分
ON-BOARD DIAGNOSTIC
DTC B1274, B1275
id070200800800
DTC B1274,
Airflow mode actuator (potentiometer) system
B1275
• Airflow mode actuator malfunction
POSSIBLE • Open circuit in wiring harness between climate control unit and airflow mode actuator
CAUSE • Short circuit in wiring harness between climate control unit (terminal P) and airflow mode actuator
(terminal C)
Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect the airflow mode actuator. (See 07-40-11 Yes Go to the next step.
AIRFLOW MODE ACTUATOR INSPECTION.) No Replace the airflow mode actuator. (See 07-40-10
• Is it normal? AIRFLOW MODE ACTUATOR REMOVAL/
INSTALLATION.)
2 • Disconnect the climate control unit connector and Yes Repair the wiring harness.
the airflow mode actuator connector. No Go to the next step.
• Is there an open circuit in the wiring harness
between the following terminals of the climate
control unit and the airflow mode actuator?
— J— B
— P— C
— C— A
3 • Is there a short circuit to ground in the wiring Yes Repair the wiring harness. 07-02
harness between climate control unit terminal P No The system is normal at present. (Clear the malfunction
and airflow mode actuator terminal C? from the memory.)
CLIMATE CONTROL UNIT CONNECTOR
AIRFLOW MODE ACTUATOR CONNECTOR
W U S Q O M K I G E C A
F * D C B A
X V T R P N L J H F D B
End Of Sie
07-02–7
1871-1U-06B(07-02).fm 8 ページ 2006年3月16日 木曜日 午後4時22分
ON-BOARD DIAGNOSTIC
DTC B1282, B1283
id070200800900
DTC B1282,
Air mix actuator (potentiometer) system
B1283
• Air mix actuator malfunction
POSSIBLE • Open circuit in wiring harness between climate control unit and air mix actuator
CAUSE • Short circuit in wiring harness between climate control unit (terminal N) and air mix actuator (terminal
C)
Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect the air mix actuator. (See 07-40-21 AIR Yes Go to the next step.
MIX ACTUATOR INSPECTION.) No Replace the air mix actuator. (See 07-40-19 AIR MIX
• Is it normal? ACTUATOR REMOVAL/INSTALLATION.)
2 • Disconnect the climate control unit connector and Yes Repair the wiring harness.
the air mix actuator connector. No Go to the next step.
• Is there an open circuit in the wiring harness
between the following terminals of the climate
control unit and the air mix actuator?
— J— A
— N— C
— C— B
3 • Is there a short circuit to ground in the wiring Yes Repair the wiring harness.
harness between climate control unit terminal N No The system is normal at present. (Clear the malfunction
and air mix actuator terminal C? from the memory.)
CLIMATE CONTROL UNIT CONNECTOR
AIR MIX ACTUATOR CONNECTOR
W U S Q O M K I G E C A
X V T R P N L J H F D B F * D C B A
End Of Sie
DTC B1947, B2014
id070200801000
DTC B1947,
Evaporator temperature sensor system
B2014
POSSIBLE • Evaporator temperature sensor malfunction
CAUSE • Open or short circuit in wiring harness between climate control unit and evaporator temperature sensor
Diagnostic Procedure
STEP INSPECTION ACTION
1 • Inspect the evaporator temperature sensor. (See Yes Go to the next step.
07-40-9 EVAPORATOR TEMPERATURE No Replace the evaporator temperature sensor. (See 07-
SENSOR INSPECTION.) 40-8 EVAPORATOR TEMPERATURE SENSOR
• Is it normal? REMOVAL/INSTALLATION.)
2 • Disconnect the climate control unit connector and Yes Repair the wiring harness.
the evaporator temperature sensor connector. No Go to the next step.
• Is there an open circuit in the wiring harness
between the following terminals of the climate
control unit and the evaporator temperature
sensor?
— F— B
— C— A
3 • Is there a short circuit to ground in the wiring Yes Repair the wiring harness.
harness between climate control unit terminal F No Connect the climate control unit connector, then go to
and evaporator temperature sensor terminal B? the next step.
07-02–8
1871-1U-06B(07-02).fm 9 ページ 2006年3月16日 木曜日 午後4時22分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
4 • Turn the ignition switch to the ON position. Yes The system is normal at present. (Clear the malfunction
• Inspect the voltage at the following climate control from the memory.)
unit terminal (wiring harness-side). No Inspect the connection of the climate control unit
— Terminal F (evaporator temperature sensor connector. (See 07-40-13 CLIMATE CONTROL UNIT
input signal) INSPECTION [FULL-AUTO AIR CONDITIONER].)
• Is the voltage normal? (Approx. 5 V)
CLIMATE CONTROL UNIT CONNECTOR
EVAPORATOR TEMPERATURE SENSOR CONNECTOR
W U S Q O M K I G E C A
B A
X V T R P N L J H F D B
End Of Sie
DTC B2832
id070200801100
Diagnostic Procedure
STEP INSPECTION ACTION
1 • Disconnect the airflow mode actuator connector. Yes Connect the connector, then go to Step 3.
• Connect battery positive voltage to airflow mode No Go to the next step.
actuator terminal D (or terminal F) and terminal F
(or terminal D) to ground.
• Does the airflow mode actuator operate?
2 • Remove the airflow mode actuator. Yes Replace the airflow mode actuator. (See 07-40-10
• Operate the airflow mode main link manually. AIRFLOW MODE ACTUATOR REMOVAL/
• Does the airflow mode main link operate INSTALLATION.)
smoothly? No Replace the airflow mode main link, airflow mode sub
link, and the airflow mode crank.
3 • Disconnect the climate control unit connector. Yes Inspect the connection of the climate control unit
• Connect battery positive voltage to climate control connector. (See 07-40-13 CLIMATE CONTROL UNIT
unit terminal O (or terminal Q) and terminal Q (or INSPECTION [FULL-AUTO AIR CONDITIONER].)
terminal O) to ground. No Repair the wiring harness.
• Does the airflow mode actuator operate?
4 • Turn the ignition switch to the ON position. Yes Recheck malfunction symptoms, then repeat from Step
• Press the MODE switch to change the mode 1 if the malfunction recurs.
(operate the airflow mode actuator) and wait for 30 No DTC troubleshooting completed.
s or more.
• Perform the DTC inspection.Is DTC B2832
indicated?
CLIMATE CONTROL UNIT CONNECTOR
AIRFLOW MODE ACTUATOR CONNECTOR
W U S Q O M K I G E C A
F * D C B A
X V T R P N L J H F D B
End Of Sie
07-02–9
1871-1U-06B(07-02).fm 10 ページ 2006年3月16日 木曜日 午後4時22分
ON-BOARD DIAGNOSTIC
DTC B2834
id070200801200
Diagnostic Procedure
STEP INSPECTION ACTION
1 • Disconnect the air mix actuator connector. Yes Connect the connector, then go to Step 3.
• Connect battery positive voltage to air mix actuator No Go to the next step.
terminal F (or terminal D) and terminal D (or
terminal F) to ground.
• Does the air mix actuator operate?
2 • Remove the air mix actuator. Yes Replace the air mix actuator. (See 07-40-19 AIR MIX
• Operate the air mix link manually. ACTUATOR REMOVAL/INSTALLATION.)
• Does the air mix link operate smoothly? No Replace the air mix link and the air mix crank.
3 • Disconnect the climate control unit connector. Yes Inspect the connection of the climate control unit
• Connect battery positive voltage to climate control connector. (See 07-40-13 CLIMATE CONTROL UNIT
unit terminal S (or terminal U) and terminal U (or INSPECTION [FULL-AUTO AIR CONDITIONER].)
terminal S) to ground. No Repair the wiring harness.
• Does the air mix actuator operate?
4 • Turn the ignition switch to the ON position. Yes Recheck malfunction symptoms, then repeat from Step
• Turn the temperature setting dial to change the set 1 if the malfunction recurs.
temperature (operate the air mix actuator) and wait No DTC troubleshooting completed.
for 30 s or more.
• Perform the DTC inspection.Is DTC B2834
indicated?
CLIMATE CONTROL UNIT CONNECTOR
AIR MIX ACTUATOR CONNECTOR
W U S Q O M K I G E C A
X V T R P N L J H F D B F * D C B A
End Of Sie
A/C OPERATION CHECK MODE
id070200801300
0 %→ 50 %→100 %→ 50 %
Air mix Actuator Air mix door
* : Shown on the information display (at the set temperature display) according to each M-MDS display.
07-02–10
1871-1U-06B(07-02).fm 11 ページ 2006年3月16日 木曜日 午後4時22分
ON-BOARD DIAGNOSTIC
A/C OPERATION CHECK MODE DISPLAY
End Of Sie
id070200801400
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (notebook PC)
— Select the “Body” tab.
• When using the PDS (pocket PC)
— Select “All Tests and Calibrations”.
3. Select the “EATC Operation Check” from the
screen menu.
4. Verify the A/C operation check mode according to
the directions on the screen.
DLC-2
End Of Sie acxuuw00000748
DTC DISPLAY
id070200801500
1. Connect the M-MDS to the DLC-2 connector.
2. Shine a 60 W incandescent light from a distance
of approx. 100 mm {3.9 in} directly onto the solar
radiation sensor.
Note
• If incandescent light is not shone on the
solar radiation sensor, the climate control
unit determines a malfunction and indicates 07-02
DTC “B1260, B1261”.
3. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
DLC-2
• When using the IDS (notebook PC)
acxuuw00000748
— Select the “Toolbox” tab.
— Select the “Self Test”.
— Select the “Module”.
— Select the “EATC”.
• When using the PDS (pocket PC)
— Select “All Tests and Calibrations”.
— Select the “EATC”.
— Select the “Self Test”.
4. Verify the DTC according to the directions on the screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
5. After completion of repairs, clear all DTCs stored in the Climate control unit. (See 07-02-11 CLEARING DTC.)
End Of Sie
CLEARING DTC
id070200801600
1. Connect the M-MDS to the DLC-2 connector.
2. Shine a fluorescent light directly onto the solar
radiation sensor.
Note
• If fluorescent light is not shone on the solar
radiation sensor, the climate control unit
determines a malfunction and indicates DTC
“B1260, B1261”.
3. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (notebook PC)
DLC-2
— Select the “Toolbox” tab.
acxuuw00000748
— Select the “Self Test”.
— Select the “Module”.
— Select the “EATC”.
• When using the PDS (pocket PC)
— Select “All Tests and Calibrations”.
— Select the “EATC”.
— Select the “Self Test”.
4. Verify the DTC according to the directions on the screen.
5. Press the clear button on the DTC screen to clear the DTC.
6. Verify that no DTCs are displayed.
End Of Sie
07-02–11
1871-1U-06B(07-02).fm 12 ページ 2006年3月16日 木曜日 午後4時22分
ON-BOARD DIAGNOSTIC
DTC TABLE
id070200801700
Memory
DTC Malfunction location Detected condition Page
function
Passenger compartment temperature (See 07-02-3 DTC B1251, B1253.)
B1251 X
Passenger sensor circuit open (See 07-02-4 DTC B1251, B1253,
compartment Passenger compartment temperature B1255, B1257, B1274, B1275, B1282,
B1253 temperature sensor sensor circuit short (body ground) X B1283, B1947, B2014 (MULTIPLE
DTCS INDICATED).)
B1255 Ambient temperature sensor circuit open X (See 07-02-5 DTC B1255, B1257.)
Ambient temperature sensor circuit short (See 07-02-4 DTC B1251, B1253,
Ambient temperature
(body ground) B1255, B1257, B1274, B1275, B1282,
B1257 sensor X B1283, B1947, B2014 (MULTIPLE
DTCS INDICATED).)
Solar radiation sensor circuit short (See 07-02-4 DTC B1260, B1261.)
B1260 X
(power supply) (See 07-02-6 DTC B1260, B1261,
Solar radiation sensor
Solar radiation sensor circuit short (body B1274, B1275, B1282, B1283
B1261 — (MULTIPLE DTCS INDICATED).)
ground)
Airflow mode actuator (potentiometer) (See 07-02-7 DTC B1274, B1275.)
B1274 X
circuit short (power supply) (See 07-02-4 DTC B1251, B1253,
Airflow mode actuator (potentiometer) B1255, B1257, B1274, B1275, B1282,
Airflow mode actuator circuit short (body ground) B1283, B1947, B2014 (MULTIPLE
(potentiometer) DTCS INDICATED).)
B1275 X (See 07-02-6 DTC B1260, B1261,
B1274, B1275, B1282, B1283
(MULTIPLE DTCS INDICATED).)
Air mix actuator (potentiometer) circuit (See 07-02-8 DTC B1282, B1283.)
B1282 X
short (power supply) (See 07-02-4 DTC B1251, B1253,
Air mix actuator (potentiometer) circuit B1255, B1257, B1274, B1275, B1282,
Air mix actuator short (body ground) B1283, B1947, B2014 (MULTIPLE
(potentiometer) DTCS INDICATED).)
B1283 X (See 07-02-6 DTC B1260, B1261,
B1274, B1275, B1282, B1283
(MULTIPLE DTCS INDICATED).)
Evaporator temperature sensor circuit (See 07-02-8 DTC B1947, B2014.)
B1947 X
short (body ground) (See 07-02-4 DTC B1251, B1253,
Evaporator
Evaporator temperature sensor circuit B1255, B1257, B1274, B1275, B1282,
temperature sensor
B2014 open X B1283, B1947, B2014 (MULTIPLE
DTCS INDICATED).)
Airflow mode actuator Airflow mode actuator motor lock
B2832 X (See 07-02-9 DTC B2832.)
(motor lock)
Air mix actuator (motor Air mix actuator motor lock
B2834 X (See 07-02-10 DTC B2834.)
lock)
U0155 CAN communication Reception error in signal from ICM (HEC) X —
U0516 system BUS OFF error X —
End Of Sie
07-02–12
1871-1U-06B(07-02).fm 13 ページ 2006年3月16日 木曜日 午後4時22分
ON-BOARD DIAGNOSTIC
PID/DATA MONITOR DISPLAY
id070200801800
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (notebook PC)
— Select the “Toolbox” tab.
— Select the “Data Logger”.
— Select the “Module”.
— Select the “EATC”.
• When using the PDS (pocket PC)
— Select the “Module Tests”.
— Select the “EATC”.
DLC-2
— Select the “Data Logger”.
acxuuw00000748
3. Select the applicable PID from the PID table
4. Verify the PID data according to the directions on
the screen.
Note
• The PID data screen function is used for monitoring the calculated value. Therefore, if the monitored value
of the output parts is not within the specification, inspection of the monitored value of input parts
corresponding to applicable output part control is necessary. In addition, because the system does not
display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output
part individually. 07-02
End Of Sie
PID/DATA MONITOR TABLE
id070200801900
End Of Sie
ACTIVE COMMAND MODES DISPLAY
id070200809400
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (notebook PC)
— Select the “Toolbox” tab.
— Select the “Data Logger”.
— Select the “Module”.
— Select the “EATC”.
• When using the PDS (pocket PC)
— Select the “Module Tests”.
— Select the “EATC”.
DLC-2
— Select the “Data Logger”.
acxuuw00002086
3. Select the active command modes from the PID
table.
4. Perform the active command modes, inspect the operations for each parts.
• If there is no operation sound from the relay, motor, and solenoid after the active command mode
inspection is performed, it is possible that there is an open or short circuit in the wiring harness, relay, motor
or solenoid, or sticking and operation malfunction.
End Of Sie
ACTIVE COMMAND MODES TABLE
id070200809500
End Of Sie
07-02–13
1871-1U-06B(07-03).fm 1 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
07-03 SYMPTOM TROUBLESHOOTING
HVAC SYSTEM WIRING DIAGRAM . . . . 07-03–2 NO.4 AIR INTAKE MODE DOES NOT
FOREWORD . . . . . . . . . . . . . . . . . . . . . . 07-03–3 CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . 07-03–7
TROUBLESHOOTING INDEX. . . . . . . . . 07-03–4 NO.5 NO TEMPERATURE CONTROL
NO.1 INSUFFICIENT AIR (OR NO AIR) WITH CLIMATE CONTROL UNIT . . . . . 07-03–10
BLOWN FROM VENTS . . . . . . . . . . . . . 07-03–4 NO.6 WINDSHIELD FOGGED . . . . . . . . . 07-03–11
NO.2 AMOUNT OF AIR BLOWN FROM NO.7 AIR FROM VENTS NOT COLD
VENTS DOES NOT CHANGE. . . . . . . . 07-03–5 ENOUGH . . . . . . . . . . . . . . . . . . . . . . . . 07-03–13
Full-auto Air Conditioner . . . . . . . . . . . 07-03–5 NO.8 NO COOL AIR . . . . . . . . . . . . . . . . . 07-03–15
NO.3 AMOUNT OF AIR BLOWN FROM NO.9 NOISE WHILE OPERATING
VENTS DOES NOT CHANGE. . . . . . . . 07-03–7 A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . 07-03–17
Manual Air Conditioner . . . . . . . . . . . . 07-03–7
End of Toc
WM: HEATER, VENTILATION AND AIR CONDITIONING (HVAC)
07-03
07-03–1
1871-1U-06B(07-03).fm 2 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
HVAC SYSTEM WIRING DIAGRAM
id070300800100
Full-auto Air Conditioner
IG2 B+
A
INFORMATION 5V
DISPLAY REFRIGERANT
PRESSURE
SWITCH MAGNETIC
PASSENGER 5V CLUTCH
B COMPARTMENT
TEMPERATURE J
SENSOR N AIR MIX
H ACTUATOR
U M
EVAPORATOR
TEMPERATURE S
SENSOR
F
P
AMBIENT AIRFLOW MODE
TEMPERATURE ACTUATOR
Q M
SENSOR
O
L
B A
I AIR INTAKE
C
ACTUATOR
CPU K M
A
E
SOLAR RADIATION BLOWER MOTOR
SENSOR BLOWER RELAY
5V T M
acxuuw00002303
07-03–2
1871-1U-06B(07-03).fm 3 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
Manual Air Conditioner
IG2 B+ B+ IG2 IG2 B+
E D
A/C RELAY
D E D E A C
TNS
BLOWER RELAY RELAY
PCM
B A C A A
MAGNETIC
A B CLUTCH
M
A
REAR
RESISTOR WINDOW 07-03
F D
DEFROSTER
A RELAY
EVAPORATOR AMBIENT
TEMPERATURE TEMPERATURE
D
D A SENSOR SENSOR
B BCM
C E
C AIRFLOW MODE
A A
ACTUATOR
INSTRUMENT
CLUSTER
M
B B
A C B F D
A D F E C F L A P B H R V X I W K G E Q S J
AIRFLOW VOLUME
CONTROL DIAL CLIMATE CONTROL UNIT
acxuuw00002304
End Of Sie
FOREWORD
id070300800200
• The areas for inspection (steps) are given according to various circuit malfunctions. Use the following chart to
verify the symptoms of the trouble in order to diagnose the appropriate area.
End Of Sie
07-03–3
1871-1U-06B(07-03).fm 4 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
TROUBLESHOOTING INDEX
id070300800300
End Of Sie
NO.1 INSUFFICIENT AIR (OR NO AIR) BLOWN FROM VENTS
id070300800400
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT AIRFLOW MODE ACTUATOR Yes Go to the next step.
• Inspect airflow mode actuator. No Repair or replace malfunctioning part in accordance with
• Is it okay? further inspection result.
2 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 5.
IS IN VENT MODE OR OTHER MODES No Go to the next step.
• Does air blow out when in the VENT mode?
3 INSPECT VENT Yes Remove obstruction, then go to Step 9.
• Is the vent clogged? No Go to the next step.
4 VERIFY THAT DUCT IN DASHBOARD IS Yes Inspect the duct for clogging, deformation and air leakage,
INSTALLED then go to Step 9.
• Is the duct in the dashboard properly No Install the duct securely in the proper position, then go to
installed? Step 9.
5 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN HEAT MODE OR DEFROSTER MODE No Inspect the vent for clogging, then go to Step 9.
• Does air blow out when in the HEAT mode?
6 INSPECT DEFROSTER MODE Yes Operation is normal. Recheck malfunction symptoms.
• Does air blow out when in the DEFROSTER No Go to the next step.
mode?
7 INSPECT VENT Yes Remove obstruction, then go to Step 9.
• Is the vent clogged? No Go to the next step.
8 VERIFY THAT DEFROSTER DUCT IS Yes Inspect the duct for clogging, deformation, and air leakage,
INSTALLED then go to the next step.
• Is the defroster duct properly installed? No Install the duct securely in proper position, then go to the
next step.
9 CONFIRM THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed.
DOES NOT RECUR AFTER REPAIR Explain repairs to customer.
• Does air blow out? No Recheck malfunction symptoms, then repeat from Step 1 if
the malfunction recurs.
07-03–4
1871-1U-06B(07-03).fm 5 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
NO.2 AMOUNT OF AIR BLOWN FROM VENTS DOES NOT CHANGE
End Of Sie
id070300800500
Full-auto Air Conditioner
2 Amount of air blown from vents does not change.
DESCRIPTION • Malfunction in blower system
• A/C unit malfunction
POSSIBLE • Blower motor malfunction
CAUSE • Malfunction in power MOS FET system
• Climate control unit malfunction
• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
performing the inspection to discover whether poor contact points are the cause of any intermittent
malfunctions. If there is a problem, inspect make sure connectors, terminals and wiring harnesses are
connected correctly and undamaged.
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT HEATER BLOWER 40 A FUSE Yes Go to the next step.
• Inspect the HEATER BLOWER 40 A fuse. No Replace the fuse, then go to Step 15. If the fuse burns out
• Is it normal? immediately, go to the next step.
2 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 4.
IS IN A/C UNIT OR ELSEWHERE No Go to the next step.
• Turn the ignition switch to the ON position.
• Turn the airflow volume control dial to ON
position.
07-03
• Recirculate air inside the vehicle.
• Does the blower motor rotate smoothly?
3 INSPECT A/C UNIT INTAKE VENT Yes Remove obstruction, then go to Step 15.
• Is A/C unit intake vent clogged? No Inspect if there are any obstruction in the A/C unit passage,
then go to Step 15.
4* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 8.
IS IN BLOWER RELAY SYSTEM OR POWER No Go to the next step.
MOS FET SYSTEM
• Turn the ignition switch to ON position.
• Turn the airflow volume control dial to OFF
position.
• Measure the voltage at the following blower
motor terminal.
— Terminal A (blower motor operation
signal)
• Is voltage approx. 12 V?
5* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (LACK OF No Repair the wiring harness between the blower relay and
CONTINUITY BETWEEN FUSE BLOCK AND HEATER BLOWER 40 A fuse, then go to Step 15.
BLOWER RELAY) OR ELSEWHERE
• Measure the voltage at the following blower
relay terminals.
— Terminal B (IG2 signal)
— Terminal A (B+ signal)
• Is the voltage approx. 12 V?
6* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (LACK OF No Repair the wiring harness between the blower relay and
CONTINUITY BETWEEN BLOWER RELAY ground, then go to Step 15.
AND GROUND) OR ELSEWHERE
• Measure the voltage at the following blower
relay terminal.
— Terminal D (GND signal)
• Is the voltage approx. 0 V?
7* INSPECT TO SEE WHETHER MALFUNCTION Yes Repair the wiring harness between the blower relay and
IS IN WIRING HARNESS (LACK OF blower motor, then go to Step 15.
CONTINUITY BETWEEN BLOWER RELAY No Replace the blower relay, then go to Step 15.
AND BLOWER MOTOR) OR BLOWER RELAY
• Measure the voltage at the following blower
relay terminal.
— Terminal C (blower motor operation
signal)
• Is the voltage approx. 12 V?
07-03–5
1871-1U-06B(07-03).fm 6 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
8* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN BLOWER MOTOR OR ELSEWHERE No Inspect the blower motor, then go to Step 15.
• Measure the voltage at the following blower
motor terminal.
— Terminal A (blower motor operation
signal)
• Is the voltage approx. 12 V?
9* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (LACK OF No Repair the wiring harness between the blower motor and
CONTINUITY BETWEEN BLOWER MOTOR
AND POWER MOS FET) OR ELSEWHERE power MOS FET, then go to Step 15.
• Measure the voltage at the following terminal
of power MOS FET.
— Terminal E (blower motor operation
signal)
• Is voltage approx. 12 V?
10* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (LACK OF No Repair the wiring harness between the power MOS FET
CONTINUITY BETWEEN POWER MOS FET
AND GROUND) OR ELSEWHERE and ground, then go to Step 15.
• Measure the voltage at the following power
MOS FET terminal.
— Terminal A (blower motor operation
signal)
• Is the voltage approx. 0 V?
11 INSPECT A/C UNIT Yes Go to the next step.
• Inspect the fan in A/C unit. No Remove obstruction, repair or replace the fan and A/C unit
— Is the fan free of interference with the A/C case, then go to Step 15.
unit case?
— Is the fan free of foreign material and
obstruction?
• Is the fan normal?
12* INSPECT TO SEE WHETHER MALFUNCTION Yes Replace the power MOS FET, then go to Step 15.
IS IN POWER MOS FET OR ELSEWHERE No Go to the next step.
• Disconnect power MOS FET connector.
• Turn the airflow volume control dial to 1st
position from OFF.
• Measure the voltage at the following power
MOS FET terminal.
— Terminal B (blower motor control signal)
• Is voltage approx. 10 V?
13* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (LACK OF No Repair the wiring harness between the power MOS FET
CONTINUITY BETWEEN POWER MOS FET
AND CLIMATE CONTROL UNIT) OR and climate control unit, then go to Step 15.
ELSEWHERE
• Turn the ignition switch to the LOCK position.
• Disconnect climate control unit connector.
• Inspect for continuity at the following
terminals between the power MOS FET and
climate control unit.
— Terminal B— T (blower motor control
signal)
— Terminal E— V (blower motor feedback
signal)
• Is there continuity?
14* INSPECT TO SEE WHETHER MALFUNCTION Yes Repair the wiring harness between the power MOS FET
IS IN CLIMATE CONTROL UNIT OR WIRING and ground, then go to the next step.
HARNESS (SHORT TO GROUND IN WIRING
HARNESS BETWEEN POWER MOS FET AND No Replace the climate control unit, then go to the next step.
CLIMATE CONTROL UNIT)
• Inspect for continuity at the following terminal
between the power MOS FET and ground.
— Terminal A (blower motor control signal)—
ground
• Is there continuity?
15 CONFIRM THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed.
DOES NOT RECUR AFTER REPAIR Explain repairs to customer.
• Is air discharged from vent? No Recheck malfunction symptoms, then repeat from Step 1 if
the malfunction recurs.
End Of Sie
07-03–6
1871-1U-06B(07-03).fm 7 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
NO.3 AMOUNT OF AIR BLOWN FROM VENTS DOES NOT CHANGE
id070300800600
Manual Air Conditioner
3 Amount of air blown from vents does not change.
DESCRIPTION • Malfunction in blower system
POSSIBLE • Blower relay, blower motor, resistor, airflow volume control dial malfunction
CAUSE • A/C unit malfunction
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT BLOWER SYSTEM Yes Go to the next step.
• Inspect the following systems and electrical No Repair or replace the malfunctioning part, then go to Step 5.
parts.
— Blower relay
— Blower motor
— Resistor
— Airflow volume control dial
— Related wiring harnesses
• Are they normal?
2 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 4.
IS IN A/C UNIT OR ELSEWHERE No Go to the next step.
• Turn the ignition switch to the ON position.
• Turn the airflow volume control dial on.
• Recirculate air inside the vehicle. 07-03
• Does the blower motor rotate smoothly?
3 INSPECT A/C UNIT Yes Go to the next step.
• Inspect blower motor. No Remove obstruction, repair or replace the fan and A/C unit
— Is the fan free of interference from the A/C case, then go to Step 5.
unit case?
— Is the fan free of foreign material and
obstructions?
• Is the fan normal?
4 INSPECT A/C UNIT INTAKE VENT Yes Remove obstruction, then go to the next step.
• Is the A/C unit intake vent clogged? No Inspect if there are any obstructions in the A/C unit passage,
then go to the next step.
5 VERIFY THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed.
OCCURS AFTER REPAIR Explain repairs to customer.
• Does air blow out? No Recheck malfunction symptoms, then repeat from Step 1 if
the malfunction recurs.
End Of Sie
NO.4 AIR INTAKE MODE DOES NOT CHANGE
id070300800700
• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
performing the inspection to discover whether poor contact points are the cause of any intermittent
malfunctions. If there is a problem, inspect to make sure connectors, terminals and wiring harnesses are
connected correctly and undamaged.
Diagnostic procedure
STEP INSPECTION ACTION
1* INSPECT AIR INTAKE ACTUATOR Yes Go to the next step.
(Auto A/C) No Replace the air intake actuator, then go to Step 9.
• Inspect the following items using M-MDS
simulation function.
— MIX_ACT (Air intake actuator)
• Is it okay?
(Manual A/C)
• Inspect air intake actuator.
• Is it okay?
07-03–7
1871-1U-06B(07-03).fm 8 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
2* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
(LACK OF CONTINUITY) IS IN AIR INTAKE No Go to Step 4.
ACTUATOR, WIRING HARNESS (BETWEEN
CLIMATE CONTROL UNIT AND AIR INTAKE
ACTUATOR) OR ELSEWHERE
• Turn the ignition switch to the ON position.
• Measure the voltages at the following climate
control unit terminals.
(Auto A/C)
— Terminal K (24-pin, FRESH motor drive
signal)
— Terminal I (24-pin, RECIRCULATE motor
drive signal)
(See 07-40-13 CLIMATE CONTROL UNIT
INSPECTION [FULL-AUTO AIR
CONDITIONER].)
(Manual A/C)
— Terminal X (24-pin, FRESH motor drive
signal)
— Terminal V (24-pin, RECIRCULATE motor
drive signal)
• Are voltages normal?
3* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 7.
(LACK OF CONTINUITY) IS IN AIR INTAKE No Repair the wiring harness between the climate control unit
ACTUATOR OR WIRING HARNESS and air intake actuator, then go to Step 9.
(BETWEEN CLIMATE CONTROL UNIT AND
AIR INTAKE ACTUATOR)
• Measure the voltages at the following air
intake actuator terminals.
(Auto A/C / Manual A/C)
— Terminal D (FRESH motor drive signal)
— Terminal F (RECIRCULATE motor drive
signal)
• Are voltages as shown below?
(Auto A/C / Manual A/C)
— Terminal D: approx. 0.5 V during
RECIRCULATE and approx. 10 V during
FRESH
— Terminal F: approx. 10 V during
RECIRCULATE and approx. 0.5 V during
FRESH
4 INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect the air intake actuator, then go to Step 9.
IS IN AIR INTAKE ACTUATOR OR No Go to the next step.
ELSEWHERE
• Disconnect the air intake actuator connector.
• Measure the voltages at the following climate
control unit terminals.
(Auto A/C)
— Terminal K (FRESH motor drive signal)
— Terminal I (RECIRCULATE motor drive
signal)
(See 07-40-13 CLIMATE CONTROL UNIT
INSPECTION [FULL-AUTO AIR
CONDITIONER].)
(Manual A/C)
— Terminal X (FRESH motor drive signal)
— Terminal V (RECIRCULATE motor drive
signal)
• Are voltages normal?
07-03–8
1871-1U-06B(07-03).fm 9 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
5 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN WIRING HARNESS (SHORT TO B+ No Repair the wiring harness between the climate control unit
BETWEEN CLIMATE CONTROL UNIT AND and air intake actuator, then go to Step 9.
AIR INTAKE ACTUATOR) OR ELSEWHERE
• Disconnect the climate control unit
connector.
• Measure the voltages at the following climate
control unit terminals.
(Auto A/C)
— Terminal K (FRESH motor drive signal)
— Terminal I (RECIRCULATE motor drive
signal)
(Manual A/C)
— Terminal X (FRESH motor drive signal)
— Terminal V (RECIRCULATE motor drive
signal)
• Are voltages approx. 0 V?
6 INSPECT TO SEE WHETHER MALFUNCTION Yes Repair the wiring harness between the climate control unit
IS IN WIRING HARNESS (SHORT TO and air intake actuator, then go to Step 9.
GROUND BETWEEN CLIMATE CONTROL No Go to the next step.
UNIT AND AIR INTAKE ACTUATOR) OR
ELSEWHERE
• Turn the ignition switch to the LOCK position.
• Inspect for continuity at the following 07-03
terminals between the climate control unit
and ground.
(Auto A/C)
— Terminal K (FRESH motor drive signal)
— Terminal I (RECIRCULATE motor drive
signal)
(Manual A/C)
— Terminal X (FRESH motor drive signal)
— Terminal V (RECIRCULATE motor drive
signal)
• Is there continuity?
7 INSPECT AIR INTAKE LINK Yes Go to the next step.
• Inspect the air intake links. No Apply grease to the links. If any the links are damaged,
— Is there grease on link? replace the air intake actuator, then go to Step 9.
— Are the links securely and properly
installed?
— Are the links free of obstructions and
hindrances?
• Are the above items normal?
8 INSPECT TO SEE WHETHER MALFUNCTION Yes Replace the climate control unit, then go to the next step.
IS IN CLIMATE CONTROL UNIT OR AIR No Remove obstruction, or install the doors in the proper
INTAKE DOOR position. If any doors are cracked or damaged, replace
• Inspect the A/C unit air intake door. them, then go to the next step.
— Is the door free of obstructions, cracks,
and damage?
— Are the doors securely and properly
installed?
• Are the above items normal?
9 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Troubleshooting completed. Explain repairs to customer.
DO NOT RECUR AFTER REPAIR No Recheck malfunction symptoms, then repeat from Step 1 if
• Does the air intake mode change smoothly? the malfunction recurs.
End Of Sie
07-03–9
1871-1U-06B(07-03).fm 10 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
NO.5 NO TEMPERATURE CONTROL WITH CLIMATE CONTROL UNIT
id070300800800
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT COOLANT TEMPERATURE Yes Go to the next step.
• Is the coolant sufficiently warmed up? No Warm up the engine, then go to Step 8.
2 INSPECT A/C UNIT AIR INTAKE SYSTEM Yes Go to the next step.
• Inspect the A/C unit air intake links, air intake No Apply grease or install the links, cranks, and rods securely
cranks, air intake rods, air intake actuator, in their proper positions, repair or replace the air intake
and wire clamp. actuator or wire clamp, then go to Step 8.
— Is there grease on links and cranks?
— Are links, cranks, and rods securely
installed in their proper positions?
— Is wire clamp free of deformation?
• Are the above items normal?
3 VERIFY THAT AIR INTAKE WIRE FROM A/C Yes Go to the next step.
UNIT IS POSITIONED SECURELY AND No Adjust the air intake wire or install securely in the correct
CORRECTLY (IF AVAILABLE) position, then go to Step 8.
• Is the air intake wire securely installed in the
correct position in relation to the A/C unit air
mix links?
4 INSPECT CLIMATE CONTROL UNIT Yes Go to the next step.
• Inspect the climate control unit. No Repair or replace the climate control unit, then go to Step 8.
• Is the climate control unit normal?
5 INSPECT A/C UNIT Yes Remove obstruction, then go to Step 8.
• Is there any foreign material or obstruction in No Go to the next step.
the A/C unit air intake doors?
6 INSPECT A/C UNIT AIR INTAKE DOOR Yes Inspect the air intake door for cracks or damage, then go to
• Is the A/C unit air intake door securely and the next step.
properly installed? No Install the air intake door securely in the proper position,
then go to the next step.
7 INSPECT HEATER LINE Yes Operation is normal. Recheck malfunction symptoms.
• Inspect the heater lines. No If heater piping connections are loose, tighten the
— Is the heater piping free of damage and connections to the specified torque.
cracks? Repair or replace the heater piping, then go to the next step.
— Are the heater piping connections free of
engine coolant leakage?
— Are the heater piping connections
securely tightened?
— Are the heater piping installation points on
A/C unit free of engine coolant leakage?
• Are the above items normal?
8 VERIFY THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed.
OCCURS AFTER REPAIR Explain repairs to customer.
• Does the unit operate in every temperature No Recheck malfunction symptoms, then repeat from Step 1 if
setting? the malfunction recurs.
End Of Sie
07-03–10
1871-1U-06B(07-03).fm 11 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
NO.6 WINDSHIELD FOGGED
id070300800900
6 Windshield fogged.
• A/C compressor does not operate while airflow mode is in DEFROSTER or HEAT/DEF modes.
DESCRIPTION • Air intake mode does not change to FRESH while airflow mode is in DEFROSTER or HEAT/DEF
modes.
• Climate control unit (B+ signal) system malfunction
POSSIBLE • Air intake actuator malfunction
CAUSE • Climate control unit (RECIRCULATE, FRESH signal) system malfunction
• A/C unit air intake door malfunction
• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, inspect to make sure connectors, terminals and wiring harness are connected correctly and
undamaged.
Diagnostic procedure
STEP INSPECTION ACTION
1 COOL AIR BLOW OUT INSPECTION Yes Go to the next step.
• When both the A/C and airflow volume No Go to Step 1 of troubleshooting index No.8.
control dial in the climate control unit are on,
does cool air blow out from the front vent?
2 INSPECT CLIMATE CONTROL UNIT POWER Yes Go to the next step.
SUPPLY FUSE FOR B+ SIGNAL No Inspect for a short to ground on blown fuse circuit.
• Is the climate control unit power supply fuse Repair or replace if necessary. Install appropriate amperage 07-03
for B+ signal normal? fuse.
3 INSPECT AIR INTAKE ACTUATOR Yes Go to the next step.
• Inspect the air intake actuator. No Apply grease or install the link properly and securely,
— Is there grease on the link? remove obstruction, then go to Step 14.
— Is the link securely and properly
positioned?
— Is the link free of obstructions?
• Are the above items normal?
*4 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
FUSE BLOCK AND CLIMATE CONTROL UNIT No Repair the wiring harness between the fuse block and
FOR CONTINUITY climate control unit, then go to Step 14.
• Disconnect the climate control unit connector
(24-pin).
• Turn the ignition switch to the ON position.
• Measure the voltage at the following climate
control unit terminal (B+ signal).
— R (full-auto air conditioner)
— P (manual air conditioner)
• Is the voltage approx. 12 V?
*5 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
CLIMATE CONTROL UNIT AND GROUND No Repair the wiring harness between the climate control unit
FOR VOLTAGE and ground, then go to Step 14.
• Measure the voltage at the following climate
control unit terminal (Ground).
— D (full-auto air conditioner)
— L (manual air conditioner)
• Is the voltage approx. 0V?
6 VERIFY WHETHER MALFUNCTION IS IN A/C Yes Go to the next step.
UNIT AIR INTAKE DOOR OR ELSEWHERE No Go to Step 12.
• Turn the ignition switch to the LOCK position.
• Connect the climate control unit connector
(24-pin).
• Remove the air intake actuator.
• Turn the ignition switch to the ON position.
• Set the airflow volume control dial to 4th
position.
• Does the air intake mode (RECIRCULATE,
FRESH) change smoothly when the air
intake link is operated by hand?
07-03–11
1871-1U-06B(07-03).fm 12 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
7 INSPECT AIR INTAKE ACTUATOR Yes Go to the next step.
• Inspect the air intake actuator. No Replace the air intake actuator, go to Step 14.
(See 07-40-10 AIR INTAKE ACTUATOR
INSPECTION.)
• Is it normal?
8 INSPECT AIR INTAKE SELECTOR SWITCH Yes Go to the next step.
AND DEFROSTER SWITCH IN CLIMATE No Replace the climate control unit, then go to Step 14.
CONTROL UNIT
(Auto A/C)
• Measure the voltage at climate control unit
connector (24-pin) terminals K and I.
(Manual A/C)
• Measure the voltage at climate control unit
connector (24-pin) terminals X and V.
• Is it normal?
*9 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
CLIMATE CONTROL UNIT AND AIR INTAKE No Repair the wiring harness between the climate control unit
ACTUATOR FOR CONTINUITY and air intake actuator, then go to Step 14.
• Turn the ignition switch to the LOCK position.
• Is there continuity between the following
climate control unit terminals and air intake
actuator terminals?
(Auto A/C)
— Terminal D — Terminal K (FRESH signal)
— Terminal F — Terminal I (RECIRCULATE
signal)
(Manual A/C)
— Terminal D — Terminal X (FRESH signal)
— Terminal F — Terminal V (RECIRCULATE
signal)
*10 INSPECT WIRING HARNESS BETWEEN Yes Repair the wiring harness between the climate control unit
CLIMATE CONTROL UNIT AND AIR INTAKE and air intake actuator, then go to Step 14.
ACTUATOR FOR SHORT TO GROUND No Go to the next step.
• Is there continuity between the following
climate control unit terminals and ground?
(Auto A/C)
— Terminal K (FRESH signal)
— Terminal I (RECIRCULATE signal)
(Manual A/C)
— Terminal X (FRESH signal)
— Terminal V (RECIRCULATE signal)
*11 INSPECT WIRING HARNESS BETWEEN Yes Repair the wiring harness between the climate control unit
CLIMATE CONTROL UNIT AND AIR INTAKE and air intake actuator, then go to Step 14.
ACTUATOR FOR SHORT TO B+ No Replace the climate control unit, then go to Step 14.
• Turn the ignition switch to the ON position
• Measure the voltage at the following climate
control unit terminals.
(Auto A/C)
— Terminal K (FRESH signal)
— Terminal I (RECIRCULATE signal)
(Manual A/C)
— Terminal X (FRESH signal)
— Terminal V (RECIRCULATE signal)
• Is the voltage approx. 12 V?
12 INSPECT A/C UNIT AIR INTAKE DOOR Yes Remove obstruction, then go to Step 14.
• Is there any foreign material or obstruction in No Go to the next step.
the A/C unit air intake door?
13 VERIFY THAT A/C UNIT AIR INTAKE DOOR Yes Inspect the air intake door for cracks or damage, then go to
IS POSITIONED SECURELY AND PROPERLY the next step.
• Is the A/C unit air intake door securely and No Install the air intake door securely in the proper position,
properly positioned? then go to the next step.
14 VERIFY THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed.
OCCURS AFTER REPAIR Explain repairs to customer.
• Does the malfunction disappear? No Recheck malfunction symptoms, then repeat from Step 1 if
the malfunction recurs.
End Of Sie
07-03–12
1871-1U-06B(07-03).fm 13 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
NO.7 AIR FROM VENTS NOT COLD ENOUGH
id070300801000
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVE BELT Yes Go to the next step.
• Inspect the drive belt. No Adjust or replace the drive belt, then go to Step 20.
(See 01-10-3 DRIVE BELT INSPECTION[L3 (See 01-10-3 DRIVE BELT REMOVAL/INSTALLATION[L3
WITH TC].) WITH TC].)
• Is it normal?
2 INSPECT REFRIGERANT SYSTEM Yes Operation is normal. (Recheck malfunction symptoms.)
PERFORMANCE No Go to the next step.
• Perform refrigerant system performance test.
(See 07-10-6 REFRIGERANT SYSTEM
PERFORMANCE TEST.)
• Is the operation normal? 07-03
3 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN A/C UNIT INTAKE AND CONDENSER No Go to Step 6.
OR ELSEWHERE
• Are the refrigerant high-pressure and low-
pressure values both high?
4 INSPECT A/C UNIT INTAKE Yes Remove obstruction, then go to Step 20. (If air does not
• Is the A/C unit intake clogged? reach the evaporator in the A/C unit, heat exchange does
not occur and refrigerant pressure becomes high.
Therefore, removal of obstruction is necessary.)
No Go to the next step.
5 INSPECT CONDENSER Yes Adjust refrigerant to the specified amount, then go to Step
• Inspect the condenser. 20. (Excessive amount of refrigerant.)
(See 07-11-18 CONDENSER No Replace the condenser, or repair and clean the condenser
INSPECTION.) fins, then go to Step 20.
• Is it normal?
6 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN EXPANSION VALVE, RECEIVER/DRIER No Go to Step 14.
AND REFRIGERANT LINES OR ELSEWHERE
• Are the refrigerant high-pressure and low-
pressure values low?
7 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN EXPANSION VALVE AND RECEIVER/ No Go to Step 10.
DRIER OR ELSEWHERE
• Immediately after the A/C compressor
operates, does the refrigerant high-pressure
value momentarily rise to correct value, then
fall and stay below it? (Is there negative
pressure on low-pressure side?)
8 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN EXPANSION VALVE OR RECEIVER/ No Replace the condenser and vacuum the refrigerant line
DRIER more than 30 min by the vacuum pump, add refrigerant to
• Turn the A/C switch off and let the air the specified level, then go to Step 20. (Since water has
conditioner stop for 10 min. intermixed in the receiver/drier and it is saturated,
• Start the engine. replacement is necessary.)
• Turn the both A/C switch and airflow volume
control dial on.
• Does the malfunction occur after the A/C
compressor turns on?
07-03–13
1871-1U-06B(07-03).fm 14 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
9 VERIFY THAT EXPANSION VALVE HEAT- Yes Replace the expansion valve, then go to Step 20. (Since the
SENSING TUBE WITHIN A/C UNIT IS valve closes too much, replacement is necessary.)
POSITIONED SECURELY AND CORRECTLY No Install the heat-sensing tube securely in the proper position,
• Is the expansion valve heat-sensing tube in then go to Step 20.
the A/C unit securely installed in the proper
position?
10 INSPECT REFRIGERANT LINE Yes Go to the next step.
• Inspect the refrigerant lines. No If the piping or A/C component (s) are damaged or cracked,
— Is the piping free of damage and cracks? replace them.
— Are the piping connections free of oil Then go to Step 20.
grime? (Visual inspection) If there is no damage, go to Step 13.
— Are the piping connections free of gas
leakage?
— Are the piping installation points on the
condenser free of gas leakage?
— Are the piping installation points on the
receiver/drier free of gas leakage?
— Are the piping installation points on the A/
C compressor free of gas leakage?
— Are the piping installation points on the A/
C unit free of gas leakage?
— Perform gas leakage inspection using a
gas leak tester.
• Are the above items normal?
11 INSPECT EVAPORATOR PIPING Yes If the vane makes a noise, add 10 ml {10 cc, 0.34 fl oz} of
CONNECTION IN A/C UNIT FOR GAS compressor oil to the A/C compressor. Verify that the noise
LEAKAGE is no longer heard.
• Are piping the connections for the evaporator Adjust refrigerant to the specified amount, then go to Step
in the A/C unit free of gas leakage? 20.
No If the piping is damaged or cracked, replace it.
Then go to Step 20.
If there is no damage, go to the next step.
12 INSPECT EVAPORATOR PIPING Yes Tighten the connections to the specified torque, adjust both
CONNECTION IN A/C UNIT FOR LOOSE compressor oil and refrigerant to the specified amount, then
• Are the piping connections for the evaporator go to Step 20.
in the A/C unit loose? No If the vane makes a noise, add 10 ml {10 cc, 0.34 fl oz} of
compressor oil to the A/C compressor. Verify that the noise
is no longer heard.
Replace the O-ring on piping, adjust refrigerant to the
specified amount, then go to Step 20.
13 INSPECT PIPING CONNECTION FOR LOOSE Yes Tighten the connections to the specified torque, adjust both
• Are the piping connections loose? compressor oil and refrigerant to the specified amount, then
go to Step 20.
No If the vane makes a noise, add 10 ml {10 cc, 0.34 fl oz} of
compressor oil to the A/C compressor. Verify that the noise
is no longer heard.
Replace O-ring on piping, adjust refrigerant to specified
amount, then go to Step 20.
14 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step. (Pressure hardly increases.)
IS IN EXPANSION VALVE, AIR MIX No Go to Step 17.
ACTUATOR AND COMPRESSOR OIL OR
ELSEWHERE
• Does the refrigerant high-pressure value
hardly increase?
15 INSPECT TO SEE WHETHER MALFUNCTION Yes Return to Step 3.
IS IN COMPRESSOR OIL AMOUNT AND A/C No Go to the next step.
COMPRESSOR OR ELSEWHERE
• When the engine is racing, does the high-
pressure value increase?
16 INSPECT TO SEE WHETHER MALFUNCTION Yes Troubleshooting completed. (Explain to customer that cause
IS IN COMPRESSOR OIL AMOUNT OR A/C was insufficient compressor oil.)
COMPRESSOR No Replace the A/C compressor, then go to Step 20. (Cause is
• After compressor oil is replenished each 10 defective A/C compressor.)
ml {10 cc, 0.34 fl oz}, does high-pressure
value increase?
07-03–14
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
17 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 19.
IS IN EXPANSION VALVE OR ELSEWHERE No Go to the next step.
• Is only refrigerant low-pressure value high?
18 VERIFY THAT AIR MIX IS INSTALLED Yes Set the airflow volume control dial to 4th position.
SECURELY AND PROPERLY Turn the A/C switch on.
• Are the A/C unit air mix links, air mix cranks, Set FRESH mode.
and air mix rods securely and properly Set temperature control to MAX COLD.
installed? Set VENT mode.
(1)Start and run the engine at 1,500 rpm for 10 min.
(2)Run the engine at idle for 1 min.
(3)Within 12 s, idle → 4,000 rpm → idle. Perform cycle 5
times.
(4) Run the engine at idle for 30 s.
(5)Drain the compressor oil completely from the A/C
compressor and verify the amount.
• If there is approx. 90 ml {90 cc, 3.0 fl oz} of
compressor oil, go to Step 20.
• If there is more than 90 ml {90 cc, 3.0 fl oz} of
compressor oil, remove surplus oil and fill the A/C
compressor with 90 ml {90 cc, 3.0 fl oz} of
compressor oil. Repeat Steps (1) to (5).
(Cause is excessive amount of compressor oil.)
No Repair or install the links, cranks and rods securely in the
proper position, then go to Step 20. 07-03
19 VERIFY THAT EXPANSION VALVE HEAT- Yes Replace the expansion valve, then go to the next step.
SENSING TUBE WITHIN A/C UNIT IS (Since the valve opens too much, replacement is
POSITIONED SECURELY AND CORRECTLY necessary.)
• Is the expansion valve heat-sensing tube in No Install the heat-sensing tube securely in the proper position,
the A/C unit securely installed in the proper then go to the next step.
position?
20 VERIFY THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed.
OCCURS AFTER REPAIR Explain repairs to customer.
• Does cool air blow out? (Are results of No Recheck malfunction symptoms, then repeat from Step 1 if
refrigerant system performance test the malfunction recurs.
normal?)
End Of Sie
NO.8 NO COOL AIR
id070300801100
8 No cool air
DESCRIPTION • Magnetic clutch does not operate.
• Malfunction in PCM A/C cut control system
• Malfunction in climate control unit
• Malfunction in refrigerant pressure switch
• Malfunction in PCM (A/C signal)
POSSIBLE • Malfunction in PCM (IG1 signal)
CAUSE • Malfunction in A/C compressor
• Malfunction in A/C relay
• Malfunction in evaporator temperature sensor
• Malfunction in BCM unit (Manual A/C)
• Malfunction in CAN communication
• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
performing the inspection to discover whether poor contact points are the cause of any intermittent
malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harnesses are
connected correctly and undamaged.
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT AIR BLOW OUT Yes Go to the next step.
• Does air blow out? No Go to Step 1 of troubleshooting indexes No.1 and 2.
2 INSPECT A/C COMPRESSOR OPERATION Yes Go to Step 1 of troubleshooting index No.7.
• Start engine. No Go to the next step.
• Turn A/C switch and airflow volume control
dial on.
• Does A/C compressor operate?
07-03–15
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
3 INSPECT FOR DTC IN PCM Yes Go to appropriate inspection procedure.
• Inspect for DTCs related to the PCM on- No (Auto A/C)
board diagnostic system. Go to the next step.
• Are any DTCs displayed? (Manual A/C)
Go to Step 5.
4 CONFIRM DTC U0073, U0516 USING M-MDS Yes Network communication, for related system is malfunction.
• Retrieve DTC from EATC and HEC. Go to appropriate inspection procedure.
• DTCs (U0073, U0516) retrieved? No Go to Step 6.
5 INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect and/or replace the PCM, then go to Step 18.
IS IN PCM OR ELSEWHERE No Release short, then go to the next step.
• Does cool air blow out when terminal 1AU of
PCM connector (A/C signal) is grounded?
6* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 8.
IS IN A/C SIGNAL CIRCUIT (BETWEEN No Go to the next step.
REFRIGERANT PRESSURE SWITCH AND
PCM) OR ELSEWHERE
• Test voltage at following terminal of
refrigerant pressure switch.
— Terminal B (A/C signal)
• Is voltage approx. 12 V?
7* INSPECT TO SEE WHETHER MALFUNCTION Yes Repair wiring harness between PCM and refrigerant
(LACK OF CONTINUITY) IS IN WIRING pressure switch, then go to Step 18.
HARNESS (BETWEEN REFRIGERANT No Inspect PCM, then go to Step 18.
PRESSURE SWITCH AND PCM) OR PCM
• Test voltage at A/C signal terminal of PCM.
• Is voltage approx. 12 V?
8 INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 10.
IS IN REFRIGERANT PRESSURE SWITCH, No (Auto A/C)
REFRIGERANT AMOUNT, OR ELSEWHERE Go to Step 11.
• Does cool air blow out when terminals A and (Manual A/C)
B of refrigerant pressure switch connector Go to the next step.
are shorted?
9* INSPECT TO SEE WHETHER MALFUNCTION Yes Go to Step 11.
IS IN WIRING HARNESS (BETWEEN No Repair wiring harness between refrigerant pressure switch
REFRIGERANT PRESSURE SWITCH AND and PCM, then go to Step 18.
PCM) OR ELSEWHERE
• Test voltage at following terminal of PCM.
— Terminal 1AU (A/C signal)
• Is voltage approx. 12 V?
10 INSPECT TO SEE WHETHER MALFUNCTION Yes If refrigerant amount is empty, replace condenser, vacuum
IS IN REFRIGERANT PRESSURE SWITCH OR refrigerant line more than 30 min by vacuum pump, and
REFRIGERANT AMOUNT add refrigerant to specified level, then go to Step 18.
• Inspect refrigerant pressure switch. No Replace refrigerant pressure switch, then go to Step 18.
• Is it okay?
11 INSPECT TO SEE WHETHER MALFUNCTION Yes Release short, then go to the next step.
(LACK OF CONTINUITY) IS IN A/C CONTROL No Go to Step 13.
SIGNAL CIRCUIT (BETWEEN A/C RELAY
AND PCM) OR ELSEWHERE
• Does cool air blow out when terminal E of A/
C relay connector (A/C control signal) is
grounded?
12* INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect PCM, then go to Step 18.
(LACK OF CONTINUITY) IS IN PCM OR No Repair wiring harness between A/C relay and PCM, then go
WIRING HARNESS (BETWEEN A/C RELAY to Step 18.
AND PCM)
• Test voltage at the A/C relay control signal
terminal of PCM.
• Is voltage approx. 12 V?
13* INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect magnetic clutch, then go to Step 18.
IS IN MAGNETIC CLUTCH OR ELSEWHERE No Go to the next step.
• Test voltage at the following terminal of
magnetic clutch thermal protector.
— Terminal A (magnetic clutch operation
signal)
• Is voltage approx. 12 V?
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
13* INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect magnetic clutch, then go to Step 18.
IS IN MAGNETIC CLUTCH OR ELSEWHERE No Go to the next step.
• Test voltage at the following terminal of
magnetic clutch thermal protector.
— Terminal A (magnetic clutch operation
signal)
• Is voltage approx. 12 V?
14 INSPECT FUSE Yes Go to the next step.
• Are A/C relay power supply fuses okay? No Replace fuse, then go to Step 18. If fuse burns out
immediately, go to the next step.
15 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
FUSE BLOCK AND A/C RELAY FOR LACK No Repair wiring harness between fuse block and A/C relay,
OF CONTINUITY then go to Step 18.
• Test voltages at following terminals of A/C
relay.
— Terminal A (A/C relay control signal)
— Terminal C (A/C control signal)
• Are voltages approx. 12 V?
16 INSPECT TO SEE WHETHER MALFUNCTION Yes Inspect wiring harness between A/C relay and magnetic
IS IN A/C RELAY OR WIRING HARNESS clutch.
(BETWEEN A/C RELAY AND MAGNETIC • If above wiring harness is OK, go to the next step.
CLUTCH) AND EVAPORATOR • If above wiring harness malfunctions, repair wiring
TEMPERATURE SENSOR harness, then go to Step 18. 07-03
• Test voltage at the following terminal of A/C No Replace A/C relay, then go to Step 18.
relay.
— Terminal D (magnetic clutch operation
signal)
• Is voltage approx. 12 V?
17 INSPECT EVAPORATOR TEMPERATURE Yes Go to the next step.
SENSOR No Replace evaporator temperature sensor, then go to the next
• Inspect evaporator temperature sensor. step.
• Is it okay?
18 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Troubleshooting completed. Explain repairs to customer.
DO NOT RECUR AFTER REPAIR No Recheck malfunction symptoms, then repeat from Step 1 if
• Does cool air blow out? (Are the results of malfunction recurs.
refrigerant system performance test okay?)
End Of Sie
NO.9 NOISE WHILE OPERATING A/C SYSTEM
id070300801200
Diagnostic procedure
STEP INSPECTION ACTION
1 CHECK A/C COMPRESSOR VANE NOISE Yes Go to Step 5.
• Is there a jingling, popping, beeping, or No Go to the next step.
buzzing sound (A/C compressor vane
noise)?
2 INSPECT A/C COMPRESSOR SLIPPAGE Yes Go to Step 14.
NOISE No Go to the next step.
• Is there a squeaking or whirling sound (A/C
compressor slippage noise)?
3 INSPECT A/C COMPRESSOR Yes Go to Step 18.
INTERFERENCE NOISE No Go to the next step.
• Is there a rattling or vibrating sound
(interference noise)?
4 INSPECT MAGNETIC CLUTCH OPERATION Yes Adjust clearance between pressure plate of magnetic clutch
NOISE and A/C compressor pulley, then go to Step 19.
• Is there a clicking sound (magnetic clutch (See 07-40-6 MAGNETIC CLUTCH ADJUSTMENT.)
operation noise)? No Condition is normal. (Recheck malfunction symptoms.)
07-03–17
1871-1U-06B(07-03).fm 18 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
5 INSPECT A/C COMPRESSOR NOISE TIME Yes Go to the next step.
• Is noise heard continuously for more than 3 No Condition is normal. (Noise occurs for 2— 3 s immediately
s after A/C compressor comes on? after A/C compressor turns on.)
6 INSPECT IDLE SPEED Yes Go to the next step.
• Inspect idle speed. No Follow the repair instruction described in section 01-10, then
(See 01-10-35 ENGINE TUNE-UP[L3 WITH go to Step 19.
TC].)
• Is it okay?
7 INSPECT REFRIGERANT AMOUNT Yes Go to Step 10.
• Inspect refrigerant amount. No Go to the next step.
• Is it okay?
8 INSPECT REFRIGERANT LINES Yes Go to the next step.
• Inspect refrigerant lines. No If piping or A/C component(s) is damaged or cracked,
— Is piping free of damage and cracks? replace then go to Step 19.
— Are piping connections free of oil grime? If there is gas leakage, repair or replace connection and
(Visual inspection) replace condenser*, then go to Step 19.
— Are piping connections free of gas
leakage?
— Are piping installation points on
condenser free of gas leakage?
— Are piping installation points on receiver/
drier free of gas leakage?
— Are piping installation points on A/C
compressor free of gas leakage?
— Are piping installation points on A/C unit
free of gas leakage
— Perform gas leak inspection using gas
leak tester.
• Are above items okay?
9 INSPECT EVAPORATOR PIPING Yes Adjust refrigerant amount to specified level, then go to Step
CONNECTIONS IN A/C UNIT FOR GAS 19.
LEAKAGE No If piping is damaged or cracked, replace then go to Step 19.
• Are piping connections for evaporator in A/C If there is gas leakage, repair or replace connection and
unit free of gas leakage? replace condenser*, then go to Step 19.
10 CHECK TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN COMPRESSOR OIL OR ELSEWHERE No Troubleshooting completed.
• Add 20 ml {20 cc, 0.8 fl oz} of compressor Explain repair to customer.
oil.
• Is noise heard when racing engine?
11 CHECK TO SEE WHETHER MALFUNCTION Yes Go to the next step.
IS IN A/C COMPRESSOR OR ELSEWHERE No Replace A/C compressor, then go to Step 19.
• Drain compressor oil.
• Is it contaminated with metal particles?
12 CHECK TO SEE WHETHER MALFUNCTION Yes Replace entire A/C system (excluding heater), then go to
IS SOMEWHERE IN A/C SYSTEM OR Step 19.
ELSEWHERE No Go to the next step.
• Is compressor oil whitish and mixed with
water?
13 INSPECT A/C COMPRESSOR OIL Yes Replace A/C compressor and condenser, then go to Step
• Is compressor oil darker than normal and 19. (Since A/C compressor may be worn and receiver/drier
contaminated with aluminum chips? may be clogged, replacement of receiver/drier is
necessary.)
No Condition is normal. Recheck malfunction symptoms.
14 CHECK TO SEE WHETHER MALFUNCTION Yes Replace A/C compressor, then go to Step 19. (A/C
IS IN A/C COMPRESSOR OR ELSEWHERE compressor discharge valve left open)
• Is noise heard immediately after A/C No Go to the next step.
compressor is stopped?
15 INSPECT DRIVE BELT Yes Go to the next step.
• Inspect drive belt. No Adjust or replace drive belt, then go to Step 19.
(See 01-10-3 DRIVE BELT INSPECTION[L3
WITH TC].)
• Is it okay?
07-03–18
1871-1U-06B(07-03).fm 19 ページ 2006年3月15日 水曜日 午前11時28分
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
16 INSPECT DRIVE BELT CONDITION Yes Remove obstruction, remove oil, or replace drive belt, then
• Is drive belt worn? go to Step 19.
• Does it have foreign material imbedded in it, No Go to the next step.
or have oil on it?
17 INSPECT MAGNETIC CLUTCH Yes Replace A/C compressor (excluding pressure plate, A/C
• Inspect magnetic clutch. compressor pulley, and stator), then go to Step 19.
(See 07-40-7 MAGNETIC CLUTCH No Replace magnetic clutch, then go to Step 19.
INSPECTION.)
• Is it okay?
18 CHECK TO SEE WHETHER MALFUNCTION Yes Visually inspect A/C compressor, replace appropriate parts
IS IN A/C COMPRESSOR OR REFRIGERANT if necessary, then go to the next step.
LINES No If noise is due to refrigerant lines, repair detached or
• Is noise emitted from A/C compressor? missing clips, tighten loose bolts, then go to the next step.
19 VERIFY THAT MALFUNCTION SYMPTOM Yes Troubleshooting completed.
OCCURS AFTER REPAIR Explain repairs to customer.
• Has A/C compressor noise stopped? No Recheck malfunction symptoms, then repeat from Step 1 if
malfunction recurs.
* : If there is gas leakage, air enters into the A/C system. The desiccant within the receiver/drier absorbs the
moisture from the air and becomes saturated. If the A/C system is used in this condition, the inside of the A/C
compressor will begin to rust due to this moisture, which may cause lock up or noise to occur. Therefore,
replacement of the receiver/drier is necessary.
07-03
End Of Sie
07-03–19
1871-1U-06B(07-10).fm 1 ページ 2006年3月15日 水曜日 午前11時29分
REFRIGERANT SYSTEM
07-10 REFRIGERANT SYSTEM
REFRIGERANT SYSTEM SERVICE Manifold Gauge Set Installation . . . . . . 07-10–2
WARNINGS . . . . . . . . . . . . . . . . . . . . . 07-10–1 REFRIGERANT CHARGING . . . . . . . . . . 07-10–2
Using/Handling Unapproved Charging Recycled R-134a
Refrigerant . . . . . . . . . . . . . . . . . . . . . 07-10–1 Refrigerant . . . . . . . . . . . . . . . . . . . . . 07-10–2
Handling Refrigerant . . . . . . . . . . . . . . 07-10–1 Charging Preparation . . . . . . . . . . . . . . 07-10–3
Storing Refrigerant. . . . . . . . . . . . . . . . 07-10–1 Evacuation. . . . . . . . . . . . . . . . . . . . . . . 07-10–3
REFRIGERANT SYSTEM SERVICE Airtightness Check . . . . . . . . . . . . . . . . 07-10–3
CAUTIONS . . . . . . . . . . . . . . . . . . . . . . 07-10–1 Charging New R-134a Refrigerant . . . . 07-10–4
Handling Insufficient Leak Test. . . . . . . . . . . . . . . . . . . . . . . . 07-10–5
Refrigerant Level . . . . . . . . . . . . . . . . 07-10–1 REFRIGERANT RECOVERY . . . . . . . . . . 07-10–6
Handling Compressor Oil. . . . . . . . . . . 07-10–2 REFRIGERANT PRESSURE CHECK . . . 07-10–6
REFRIGERANT SYSTEM GENERAL REFRIGERANT SYSTEM
PROCEDURES . . . . . . . . . . . . . . . . . . . 07-10–2 PERFORMANCE TEST . . . . . . . . . . . . . 07-10–6
End of Toc
REFRIGERANT SYSTEM SERVICE WARNINGS
WM: REFRIGERANT SYSTEM
id071000800100
Using/Handling Unapproved Refrigerant
• Using a flammable refrigerant, such as OZ-12, in this vehicle is dangerous. In an accident, the
refrigerant may catch fire, resulting in serious injury or death. When servicing this vehicle, use only R-
134a. 07-10
• Checking for system leakage on a vehicle that has been serviced with flammable refrigerant, such as
OZ-12, is dangerous. Conventional leak detectors use an electronically generated arc which can ignite
the refrigerant, causing serious injury or death. If a flammable refrigerant may have been used to
service the system, or if you suspect a flammable refrigerant has been used, contact the local fire
marshal or EPA office for information on handling the refrigerant.
Handling Refrigerant
• Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and
throat. Also, due to environmental concerns, use service equipment certified to meet the requirements
of SAE J2210 (R-134a recycling equipment) when draining R-134a from the air conditioning system. If
accidental system discharge occurs, ventilate work area before resuming service.
• Do not pressure test or leak test R-134a service equipment and/or vehicle air conditioning system with
compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated
pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and
safety information may be obtained from refrigerant manufacturers.
• Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas may be generated if
the refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out any
operation that can cause refrigerant leakage, extinguish or remove the above-mentioned heat sources
and maintain adequate ventilation.
• Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostbite. When
handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes,
immediately wash them with clean water and consult a doctor.
Storing Refrigerant
• The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode,
scattering metal fragments and liquid refrigerant that can seriously injure you. Store the refrigerant at
temperatures below 40°C {104°F}.
End Of Sie
REFRIGERANT SYSTEM SERVICE CAUTIONS
id071000800200
Handling Insufficient Refrigerant Level
• If an insufficient refrigerant level is detected at troubleshooting, do not charge (add) the refrigerant.
Because an accurate amount of refrigerant cannot be determined from the pressure indicated on the
manifold gauge, never charge the refrigerant. If there is too much or too little refrigerant from the
refilling, there may be secondary problems such as damage to the refrigerant cycle parts, or a decrease
of cooling performance. Therefore, if it is determined that the refrigerant level is insufficient,
completely remove refrigerant from the refrigerant cycle and refill with refrigerant to the specified
amount.
07-10–1
1871-1U-06B(07-10).fm 2 ページ 2006年3月15日 水曜日 午前11時29分
REFRIGERANT SYSTEM
Handling Compressor Oil
• Use only ATMOS GU10 compressor oil for this vehicle. Using a PAG oil other than ATMOS GU10
compressor oil can damage the A/C compressor.
• Do not spill ATMOS GU10 compressor oil on the vehicle. A drop of compressor oil on the vehicle
surface can eat away at the paint. If oil gets on the vehicle, wipe it off immediately.
• ATMOS GU10 compressor oil (PAG oil) has a ATMOS GU10 COMPRESSOR OIL (PAG OIL)
higher moisture absorption efficiency than the
MOISTURE ABSORPTION
previously used mineral oil. If moisture mixes
with the compressor oil, the refrigerant
system could be damaged. Therefore, install
caps immediately after using the compressor
oil or removing refrigerant system parts to
prevent moisture absorption.
• If the refrigerant gas is completely discharged MINERAL OIL
from the system for reasons such as a
malfunction during A/C operation, repair or 0
TIME
replace the malfunctioning part, charge the
acxuuw00000767
refrigerant to the specified amount and always
add 60 ml {60 cc, 2.03 fl oz} of A/C
compressor. If the compressor oil is not adequately replenished, the A/C compressor may quickly
deteriorate, abnormal noise may develop, cooling performance may be affected or, in the worst case,
the A/C compressor may seize.
End Of Sie
REFRIGERANT SYSTEM GENERAL PROCEDURES
id071000800300
Manifold Gauge Set Installation
1. Fully close the valves of the manifold gauge.
2. Connect the charging hoses to the high and low-
pressure side joints of the manifold gauge.
3. Connect the quick couplers to the ends of the
charging hoses.
4. Connect the quick couplers to the charging MANIFOLD GAUGE
valves.
End Of Sie CHARGING HOSE
WM: REFRIGERANT
QUICK COUPLER
CAP
CAP
CHARGING
CHARGING VALVE OF VALVE OF
LOW-PRESSURE SIDE HIGH-PRESSURE
SIDE
acxuuw00001560
REFRIGERANT CHARGING
id071000800400
Caution
• Do not exceed the specification when charging the system with refrigerant. Doing so will decrease
the efficiency of the air conditioner or damage the refrigeration cycle parts.
07-10–2
1871-1U-06B(07-10).fm 3 ページ 2006年3月15日 水曜日 午前11時29分
REFRIGERANT SYSTEM
Charging Preparation
1. Install the manifold gauge set.
2. Connect the tap pin side of the charging hose to the air purge valve of the manifold gauge.
3. Connect the vacuum pump hose to the center joint of the manifold gauge.
4. Connect the vacuum pump hose to the vacuum pump.
5. Connect the charging hose to the refrigerant tank.
6. Place the refrigerant tank on the scale.
SCALE
VACUUM PUMP
acxuuw00000768
Evacuation 07-10
1. Open all the valves of the manifold gauge.
Caution
• Close the manifold gauge valve immediately after stopping the vacuum pump. If the valve is left
open, the vacuum pump oil will flow back into the refrigeration cycle and cause a decrease in the
efficiency of the air conditioner.
CLOSE
acxuuw00000769
acxuuw00000770
Airtightness Check
1. Stop the vacuum pump and wait for 5 min.
2. Check the high- and low-pressure side readings of the manifold gauge.
• If the reading has changed, inspect for leakage and go to Evacuation. (See 07-10-3 Evacuation.)
• If the reading has not changed, go to Charging New R-134a Refrigerant. (See 07-10-4 Charging New R-
134a Refrigerant.)
07-10–3
1871-1U-06B(07-10).fm 4 ページ 2006年3月15日 水曜日 午前11時29分
REFRIGERANT SYSTEM
Charging New R-134a Refrigerant
1. Open the valve of the refrigerant tank.
2. Weigh the refrigerant tank to charge the suitable amount of refrigerant.
Warning
• If the refrigerant system is charged with a large amount of refrigerant when inspecting for gas
leakage, and if any leakage should occur, the refrigerant will be released into the atmosphere. In
order to prevent the accidental release of refrigerant which can destroy the ozone layer in the
stratosphere, follow the proper procedures and charge with only a small amount of refrigerant
when inspecting for gas leakage.
• If charging the system with refrigerant using service cans, running the engine with the high-
pressure side valve open is dangerous. Pressure within the service cans will increase and the
cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure
you. Therefore, do not open the high-pressure side valve while the engine is running.
Caution
• Always being charging of refrigerant from the high-pressure side. If changing is begun from the
low-pressure side, the vanes of the A/C compressor will not be released and abnormal noise may
result.
OPEN
acxuuw00000771
Warning
• If charging the system with refrigerant using service cans, running the engine with the high-
pressure side valve open is dangerous. Pressure within the service cans will increase and the
cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure
you. Therefore, do not open the high-pressure side valve while the engine is running.
07-10–4
1871-1U-06B(07-10).fm 5 ページ 2006年3月15日 水曜日 午前11時29分
REFRIGERANT SYSTEM
7. Open the high-pressure side valve of the manifold
gauge and charge with refrigerant until the weight MANIFOLD GAUGE
of refrigerant tank has decreased 250 g {8.83 oz}
from the amount in Step 2.
OPEN
acxuuw00000771
acxuuw00000773
Leak Test
1. Inspect for leakage using the a gas leak tester.
• If there is no leakage, go to Step 3.
• If leakage is found at a loose joint, tighten the joint, then go to the next step.
2. Inspect for leakage again.
• If there is no leakage after tightening the joint, go to the next step.
• If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the
charging procedure from evacuation.
3. Disconnect the manifold gauge from the charging valves.
4. Install the caps to the charging valves.
End Of Sie
CAP
CAP
acxuuw00000774
07-10–5
1871-1U-06B(07-10).fm 6 ページ 2006年3月15日 水曜日 午前11時29分
REFRIGERANT SYSTEM
REFRIGERANT RECOVERY
id071000800500
Warning
• Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose
and throat. Also, due to environmental concerns, use service equipment certified to meet the
requirements of SAE J2210 (R-134a recycling equipment) when draining R-134a from the air
conditioning system. If accidental system discharge occurs, ventilate work area before resuming
service.
1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer's
instructions.
End Of Sie
REFRIGERANT PRESSURE CHECK
id071000800600
1. Connect the manifold gauge. (See 07-10-2 REFRIGERANT SYSTEM GENERAL PROCEDURES.)
2. Start the engine and after it is warmed up, run it at a constant 1,500 rpm.
3. Set the fan speed MAX HI.
4. Turn the A/C switch on.
5. Set to RECIRCULATE mode.
6. Set the temperature control to MAX COLD.
7. Set to VENT mode.
8. Close all the doors and all the windows.
9. Measure the ambient temperature and high- and low- pressure side reading of the manifold gauge.
10. Verify that the intersection of the pressure reading of the manifold gauge and ambient temperature is in the
shaded zone.
• If there is any malfunction, inspect the
refrigerant system according to the MPa
{kgf/cm2, psi} HIGH-PRESSURE SIDE
troubleshooting chart.
PRESSURE READING OF MANIHOLD GAUGE
2.5
End Of Sie {25, 355}
2.0
{20, 284}
1.5
{15, 213}
1.0
{10, 142}
LOW-PRESSURE SIDE
0.15
{1.5, 22}
0.10
{1.0, 14}
10 15 20 25 30 35 40
{50} {59} {68} {77} {86} {95} {104}
AMBIENT TEMPERATURE °C {°F}
acxuuw00000775
07-10–6
1871-1U-06B(07-10).fm 7 ページ 2006年3月15日 水曜日 午前11時29分
REFRIGERANT SYSTEM
12. Verify the ambient temperature.
13. Verify that the temperature reading is in the shaded zone.
• If the there is any malfunction, inspect the °C {°F}
refrigerant system according to the 9 {48}
CENTER VENTILATOR
troubleshooting chart.
7 {45}
End Of Sie
TEMPERATURE
5 {41}
3 {37}
1 {34}
10 15 20 25 30 35 40
{50} {59} {68} {77} {86} {95} {104}
AMBIENT TEMPERATURE °C {°F}
acxuuw00000687
07-10
07-10–7
1871-1U-06B(07-11).fm 1 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
07-11 BASIC SYSTEM
BASIC SYSTEM LOCATION INDEX. . . . 07-11–2 AIR FILTER
A/C UNIT REMOVAL/INSTALLATION . . . . . . . . . . 07-11–12
REMOVAL/INSTALLATION. . . . . . . . . . 07-11–2 AIR FILTER INSPECTION . . . . . . . . . . . . 07-11–12
A/C Unit Installation Note . . . . . . . . . . . 07-11–4 REAR HEAT DUCT
A/C UNIT REMOVAL/INSTALLATION . . . . . . . . . . 07-11–13
DISASSEMBLY/ASSEMBLY . . . . . . . . . 07-11–4 A/C COMPRESSOR
Sensor Clamp Assembly Note . . . . . . . 07-11–6 REMOVAL/INSTALLATION . . . . . . . . . . 07-11–13
Evaporator Temperature Sensor A/C Compressor Installation Note. . . . . 07-11–14
Assembly Note . . . . . . . . . . . . . . . . . . 07-11–6 REFRIGERANT LINES
Adhesive polyurethane (2) REMOVAL/INSTALLATION . . . . . . . . . . 07-11–15
Assembly Note . . . . . . . . . . . . . . . . . . 07-11–6 Refrigerant Line Removal Note . . . . . . . 07-11–16
Adhesive polyurethane (4) Refrigerant Line Installation Note . . . . . 07-11–16
Assembly Note . . . . . . . . . . . . . . . . . . 07-11–7 CONDENSER
Adhesive polyurethane (3) REMOVAL/INSTALLATION . . . . . . . . . . 07-11–17
Assembly Note . . . . . . . . . . . . . . . . . . 07-11–7 Condenser Installation Note . . . . . . . . . 07-11–18
Adhesive polyurethane (1) CONDENSER INSPECTION . . . . . . . . . . 07-11–18
Assembly Note . . . . . . . . . . . . . . . . . . 07-11–7 RECEIVER/DRIER
EXPANSION VALVE REMOVAL/INSTALLATION . . . . . . . . . . 07-11–19
REMOVAL/INSTALLATION. . . . . . . . . . 07-11–8 Receiver/Drier Removal Note . . . . . . . . 07-11–19
BLOWER UNIT Receiver/Drier Installation Note . . . . . . 07-11–20
REMOVAL/INSTALLATION. . . . . . . . . . 07-11–9 EVAPORATOR INSPECTION. . . . . . . . . . 07-11–20 07-11
BLOWER UNIT HEATER CORE INSPECTION . . . . . . . . . 07-11–20
DISASSEMBLY/ASSEMBLY . . . . . . . . . 07-11–11
End of Toc
WM: HVAC BASIC SYSTEM
07-11–1
1871-1U-06B(07-11).fm 2 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
BASIC SYSTEM LOCATION INDEX
id071100800100
1
2
9 3
4
8
5
7
acxuuw00000688
End Of Sie
A/C UNIT REMOVAL/INSTALLATION
WM: HEATER UNIT
id071100800200
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07-10-6 REFRIGERANT RECOVERY.) (See 07-10-2
REFRIGERANT CHARGING.)
3. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT[L3 WITH TC].)
4. Remove the following parts:
(1) Console panel (See 09-17-15 CONSOLE PANEL REMOVAL/INSTALLATION.)
(2) Console (See 09-17-13 CONSOLE REMOVAL/INSTALLATION.)
(3) Front scuff plate inner (See 09-17-19 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(4) Front side trim (See 09-17-18 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
(5) Dashboard under cover
(6) Glove compartment (See 09-17-8 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
(7) Hood release lever (See 09-14-25 HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION.)
(8) Lower panel (See 09-17-9 LOWER PANEL REMOVAL/INSTALLATION.)
(9) Center panel (See 09-17-8 CENTER PANEL REMOVAL/INSTALLATION.)
(10)Audio unit (See 09-20-4 AUDIO UNIT REMOVAL/INSTALLATION.)
07-11–2
1871-1U-06B(07-11).fm 3 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
(11)Climate control unit (See 07-40-25 CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO
AIR CONDITIONER].) (See 07-40-25 CLIMATE CONTROL UNIT REMOVAL [MANUAL AIR
CONDITIONER].) (See 07-40-26 CLIMATE CONTROL UNIT INSTALLATION [MANUAL AIR
CONDITIONER].)
(12)Knee bolster (See 09-17-12 KNEE BOLSTER REMOVAL/INSTALLATION.)
(13)Meter hood (See 09-17-10 METER HOOD REMOVAL/INSTALLATION.)
(14)Column cover (See 09-17-8 COLUMN COVER REMOVAL/INSTALLATION.)
(15)Instrument cluster (See 09-22-2 INSTRUMENT CLUSTER REMOVAL/INSTALLATION.)
(16)Driver-side air bag module (See 08-10-6 DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
(17)Steering wheel (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(18)Combination switch (See 09-18-13 COMBINATION SWITCH REMOVAL/INSTALLATION.)
(19)Steering shaft (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(20)A-pillar lower trim (See 09-17-16 A-PILLAR LOWER TRIM REMOVAL/INSTALLATION.)
(21)A-pillar trim (See 09-17-15 A-PILLAR TRIM REMOVAL/INSTALLATION.)
(22)Dashboard (See 09-17-4 DASHBOARD REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table. Do not allow compressor oil to spill.
1
2
07-11
R
3
4
acxuuw00002320
.
1 Insulator
2 Heater hose
3 Cooler hose (LO)
(See 07-11-15 REFRIGERANT LINES REMOVAL/
INSTALLATION.)
4 Cooler pipe
(See 07-11-15 REFRIGERANT LINES REMOVAL/
INSTALLATION.)
5 A/C unit
(See 07-11-4 A/C Unit Installation Note.)
6. Install in the reverse order of removal.
7. Perform the refrigerant system performance test.
(See 07-10-6 REFRIGERANT SYSTEM
PERFORMANCE TEST.)
5
acxuuw00000692
07-11–3
1871-1U-06B(07-11).fm 4 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
A/C Unit Installation Note
1. When installing a new A/C unit or evaporator, add a supplemental amount of ATMOS GU10 compressor oil into
the refrigerant cycle.
End Of Sie
A/C UNIT DISASSEMBLY/ASSEMBLY
id071100800300
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
4
29 19
9
30 7
6
27 8 5
31 25
33 R
34 32 22
1
35 R
24 R
3.5—5.5 6.8—9.8
26 {36—56, 23 {70—99,
28 R 31—48} R 61—86}
21
R
11 10
18 14
15
13
17
N·m {kgf·cm, in·lbf}
acxuuw00001833
07-11–4
1871-1U-06B(07-11).fm 5 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
4
29 19
9
30 7
6
27 8 5
31 25
33 R
32 22
34 1
R
35 20 24 R
3.5—5.5 6.8—9.8
26 {36—56, 23 {70—99, 07-11
R 31—48} R 61—86}
28
21
R
10
18 14 12
15
17
16
N·m {kgf·cm, in·lbf}
acxuuw00001834
07-11–5
1871-1U-06B(07-11).fm 6 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
Sensor Clamp Assembly Note
1. Attach the sensor clamp as shown in the figure.
SENSOR PART
SECURE AT END
OF CLAMP LOCK SECURELY
RIGHT WRONG
acxuuw00000696
acxuuw00000695
ADHESIVE
POLYURETHANE (2)
acxuuw00000697
HIGH PRESSURE
SIDE PIPE
ADHESIVE
POLYURETHANE (2)
acxuuw00000698
07-11–6
1871-1U-06B(07-11).fm 7 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
Adhesive polyurethane (4) Assembly Note
1. Attach the adhesive polyurethane (4) so that it
adheres around the expansion valve.
EXPANSION
VALVE
ADHESIVE
POLYURETHANE (4)
acxuuw00000699
End Of Sie
07-11–7
1871-1U-06B(07-11).fm 8 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
EXPANSION VALVE REMOVAL/INSTALLATION
id071100800400
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07-10-6 REFRIGERANT RECOVERY.) (See 07-10-2
REFRIGERANT CHARGING.)
Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug open fittings after removing any refrigeration
cycle parts to keep moisture or foreign material out of the cycle.
Caution
• Being careful not to damage the adhesive sponge rubber or adhesive polyurethane, remove
adhesive polyurethane completely.
10. Remove the one bolt and shift the evaporator pipe. Do not allow compressor oil to spill.
11. Remove the two bolts.
12. Remove the expansion valve. Do not allow compressor oil to spill.
13. Remove the screws and plate.
14. Remove the adhesive polyurethane (2). (See 07-11-4 A/C UNIT DISASSEMBLY/ASSEMBLY.)
Caution
• Being careful not to damage the adhesive sponge rubber or adhesive polyurethane, remove
adhesive polyurethane completely.
15. Remove the adhesive polyurethane (3). (See 07-11-4 A/C UNIT DISASSEMBLY/ASSEMBLY.)
Caution
• Being careful not to damage the adhesive sponge rubber or adhesive polyurethane, remove
adhesive polyurethane completely.
07-11–8
1871-1U-06B(07-11).fm 9 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
16. Remove the adhesive polyurethane (4). (See 07-11-4 A/C UNIT DISASSEMBLY/ASSEMBLY.)
EVAPORATOR PIPE
ADHESIVE
POLYURETHANE (3)
6.8—9.8
{70—99,
61—86}
DUCT (1)
R
ADHESIVE
ADHESIVE POLYURETHANE (4)
POLYURETHANE (1)
ADHESIVE
POLYURETHANE (2)
SHIFT
R
ADHESIVE 07-11
POLYURETHANE (4)
R R
R
PLATE
R
3.5—5.5
{36—56,
EXPANSION VALVE 31—48}
id071100800500
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Console panel (See 09-17-15 CONSOLE PANEL REMOVAL/INSTALLATION.)
(2) Console (See 09-17-13 CONSOLE REMOVAL/INSTALLATION.)
(3) Front scuff plate inner (See 09-17-19 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(4) Front side trim (See 09-17-18 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
(5) Dashboard under cover
(6) Glove compartment (See 09-17-8 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
(7) Hood release lever (See 09-14-25 HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION.)
(8) Lower panel (See 09-17-9 LOWER PANEL REMOVAL/INSTALLATION.)
(9) Center panel (See 09-17-8 CENTER PANEL REMOVAL/INSTALLATION.)
(10)Audio unit (See 09-20-4 AUDIO UNIT REMOVAL/INSTALLATION.)
(11)Climate control unit (See 07-40-25 CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO
AIR CONDITIONER].) (See 07-40-25 CLIMATE CONTROL UNIT REMOVAL [MANUAL AIR
CONDITIONER].) (See 07-40-26 CLIMATE CONTROL UNIT INSTALLATION [MANUAL AIR
CONDITIONER].)
(12)Knee bolster (See 09-17-12 KNEE BOLSTER REMOVAL/INSTALLATION.)
(13)Meter hood (See 09-17-10 METER HOOD REMOVAL/INSTALLATION.)
(14)Column cover (See 09-17-8 COLUMN COVER REMOVAL/INSTALLATION.)
(15)Instrument cluster (See 09-22-2 INSTRUMENT CLUSTER REMOVAL/INSTALLATION.)
(16)Driver-side air bag module (See 08-10-6 DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
(17)Steering wheel (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(18)Combination switch (See 09-18-13 COMBINATION SWITCH REMOVAL/INSTALLATION.)
(19)Steering shaft (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
07-11–9
1871-1U-06B(07-11).fm 10 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
(20)A-pillar lower trim (See 09-17-16 A-PILLAR LOWER TRIM REMOVAL/INSTALLATION.)
(21)A-pillar trim (See 09-17-15 A-PILLAR TRIM REMOVAL/INSTALLATION.)
(22)Dashboard (See 09-17-4 DASHBOARD REMOVAL/INSTALLATION.)
3. Remove the blower motor. (See 07-40-8 BLOWER MOTOR REMOVAL/INSTALLATION.)
4. Remove the power MOS FET (Full-auto air conditioner) or resistor. (Manual air conditioner) (See 07-40-4
POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR (POWER MOS FET) REMOVAL/
INSTALLATION.) (See 07-40-7 RESISTOR REMOVAL/INSTALLATION.)
5. Remove the blower unit installation nuts.
6. Remove the screw securing the duct (2) to the A/C unit, by inserting a phillips screwdriver into the hole made
after removing the blower motor.
7. Remove the screw securing the duct (2) to the A/C unit.
8. Remove the duct (2).
INSTALLATION
HOLE OF THE
BLOWER MOTOR
DUCT (2)
SCREW
SCREW SCREW
acxuuw00000702
BLOWER UNIT
acxuuw00000703
07-11–10
1871-1U-06B(07-11).fm 11 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
13. Install the screw on the end of the phillips
screwdriver with the packing tape.
SCREW
Caution
• If the packing tape remains in the duct
(2), it may become a source of noise.
Wind up the packing tape to prevent
pinching when tightening the screw. PACKING TAPE
PHILLIPS
SCREWDRIVER
14. Install the duct (2) to the A/C unit by inserting a
phillips screwdriver, with the screw, into the hole
made after removing the blower motor.
acxuuw00000704
15. Pull out the phillips screwdriver together with the
packing tape.
16. Install in the reverse order of removal.
End Of Sie
BLOWER UNIT DISASSEMBLY/ASSEMBLY
id071100800600
1. Disassemble in the order indicated in the table.
Caution
• Apply only the specified grease to the link. Otherwise abnormal noise or improper operation may
result.
07-11
8 6
9
5
3
7
4
2
1
acxuuw00001562
07-11–11
1871-1U-06B(07-11).fm 12 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
AIR FILTER REMOVAL/INSTALLATION
id071100800700
Caution
• If the air conditioner is used or the vehicle is driven with the air filter removed, snow or foreign
material can penetrate the blower motor, causing motor lock or damage. As a result, low visibility
due to window fogging or air conditioner malfunction could occur. Do not use the air conditioner
or drive the vehicle with the air filter removed.
1
AIR FILTER ATTACHMENT
DIRECTION
acxuuw00000705
Note
• The air filter cannot be reused by cleaning it with water or compressed air.
End Of Sie
WM: REAR HEAT DUCT
07-11–12
1871-1U-06B(07-11).fm 13 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
REAR HEAT DUCT REMOVAL/INSTALLATION
id071100800900
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Front seat (See 09-13-2 FRONT SEAT REMOVAL/INSTALLATION.)
(2) Car-navigation unit (With car-navigation system) (See 09-20-5 CAR-NAVIGATION UNIT REMOVAL/
INSTALLATION.)
(3) Front scuff plate inner (See 09-17-19 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(4) Front side trim (See 09-17-18 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
(5) Console panel (See 09-17-13 CONSOLE REMOVAL/INSTALLATION.)
(6) Console (See 09-17-13 CONSOLE REMOVAL/INSTALLATION.)
3. Turn over the floor covering. (See 09-17-28 FLOOR COVERING REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table. .
07-11
acxuuw00000706
A/C COMPRESSOR REMOVAL/INSTALLATION
id071100801000
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07-10-6 REFRIGERANT RECOVERY.) (See 07-10-2
REFRIGERANT CHARGING.)
3. Remove the splash shield.
4. Loosen the drive belt and remove it.
Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug open fittings after removing any refrigeration
cycle parts to keep moisture or foreign material out of the cycle.
5. Remove in the order indicated in the table. Do not
allow compressor oil to spill. .
acxuuw00000707
07-11–13
1871-1U-06B(07-11).fm 14 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
A/C Compressor Installation Note
Caution
• Due to the high moisture-absorption characteristics of the compressor oil, it may absorb moisture
if left over a long period of time thereby negatively affecting A/C operation. Drain the compressor
oil and refill within 10 min. of each other.
1. Rotate new A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a clean measuring
device. Use this refrigerant oil to refill new A/C compressor. Do not allow refrigerant oil to become
contaminated.
2. Rotate old A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a separate, clean
measuring device.
3. Compare those oil amounts. The amount of the oil drained from the new A/C compressor should be greater
than the old one.
4. Pour the same amount oil of drained from the old A/C compressor back into the new A/C compressor.
SAME AMOUNT
NEW A/C
COMPRESSOR
acxuuw00000708
07-11–14
1871-1U-06B(07-11).fm 15 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
REFRIGERANT LINES REMOVAL/INSTALLATION
id071100801100
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07-10-6 REFRIGERANT RECOVERY.) (See 07-10-2
REFRIGERANT CHARGING.)
3. Disconnect the body earth cable installed to No.3 engine mount rubber.
4. Disconnect the insulator. (See 07-11-2 A/C UNIT REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table. Do not allow compressor oil to spill.
Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug all open fittings after removing any
refrigeration cycle parts to keep moisture or foreign material out of the cycle.
R 07-11
B
A 2
a B
1
R
a
R
R
a
acxuuw00002321
07-11–15
1871-1U-06B(07-11).fm 16 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
Refrigerant Line Removal Note
Spring-lock coupling type
1. Set the SST.
acxuuw00000784
acxuuw00000785
Note
• The male pipe or hose can be disconnected
MALE PIPE OR HOSE
easily from the female pipe by pulling from
the male pipe or hose while maintaining the
pressure of the protruding part of the SST.
07-11–16
1871-1U-06B(07-11).fm 17 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
Spring-lock coupling type
1. Connect the male pipe or hose by pushing it while
MALE PIPE OR HOSE
slightly twisting it onto female pipe until the garter
spring at the male pipe or hose is over the flared SLIGHTLY TWISTING
FLARED END
end of female pipe.
FEMALE PIPE
Note
• When the male pipe or hose is replaced, the
indicator ring comes out after connecting to
indicate that it is locked. PUSHING
GARTER SPRING
End Of Sie
WM: CONDENSER
SPRING IS OVER
CAGE GARTER SPRING THE FLARED END
SECTION
FLARED
END
CONDENSER REMOVAL/INSTALLATION
id071100801200
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07-10-6 REFRIGERANT RECOVERY.) (See 07-10-2
REFRIGERANT CHARGING.)
3. Remove the air cleaner. (See 01-13-5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION[L3 WITH TC].)
4. Remove the splash shield.
5. Drain the engine coolant. (See 01-12-5 ENGINE COOLANT REPLACEMENT[L3 WITH TC].)
6. Remove the following parts:
(1) Charge air cooler duct, air cleaner and fresh air duct component (See 01-13-5 INTAKE AIR SYSTEM
REMOVAL/INSTALLATION[L3 WITH TC].)
(2) Coolant reserve tank (See 01-12-7 COOLANT RESERVE TANK REMOVAL/INSTALLATION[L3 WITH TC].)
(3) Dipstick pipe (See 01-11-6 OIL PAN REMOVAL/INSTALLATION[L3 WITH TC].)
(4) Cooling fan component (See 01-12-12 FAN MOTOR REMOVAL/INSTALLATION[L3 WITH TC].)
7. Remove the radiator. (See 01-12-8 RADIATOR REMOVAL/INSTALLATION[L3 WITH TC].)
Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug all open fittings after removing any
refrigeration cycle parts to keep moisture or foreign material out of the cycle.
8. Remove in the order indicated in the table. Do not allow compressor oil to spill.
07-11–17
1871-1U-06B(07-11).fm 18 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
9. Install in the reverse order of removal.
6.8—9.8 N·m
{69.4—99.9 kgf·cm,
61.6—88.7 in·lbf}
3
R 2
R
acxuuw00002305
1 Nut 4 Condenser
(See 07-11-17 CONDENSER REMOVAL/
2 Cooler hose (HI)
INSTALLATION.)
(See 07-11-15 REFRIGERANT LINES REMOVAL/
INSTALLATION.)
3 Cooler pipe
(See 07-11-15 REFRIGERANT LINES REMOVAL/
INSTALLATION.)
10. Perform the refrigerant system performance test. (See 07-10-6 REFRIGERANT SYSTEM PERFORMANCE
TEST.)
End Of Sie
CONDENSER INSPECTION
id071100801300
1. Inspect for cracks, damage, and oil leakage.
• If any are found, replace the condenser.
2. Inspect for fins clogged by dust.
• If any are clogged, remove the dust from the fins.
3. Inspect for bent fins.
• If any are bent, use a flathead screwdriver to straighten them.
End Of Sie
WM: RECEIVER/DRIER
07-11–18
1871-1U-06B(07-11).fm 19 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
RECEIVER/DRIER REMOVAL/INSTALLATION
id071100801400
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See 07-10-6 REFRIGERANT RECOVERY.) (See 07-10-2
REFRIGERANT CHARGING.)
3. Remove the front bumper. (See 09-10-2 FRONT BUMPER REMOVAL/INSTALLATION.)
4. Remove the oil cooler. (See 01-11-6 OIL COOLER REMOVAL/INSTALLATION[L3 WITH TC].)
Caution
• If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug all open fittings after removing any
refrigeration cycle parts to keep moisture or foreign material out of the cycle.
5. Remove the receiver/drier. Do not allow compressor oil to spill. (See 07-11-19 Receiver/Drier Removal Note.)
RECEIVER/DRIER
6.85—9.80 N·m
{70.0—99.9 kgf·cm,
60.8—86.7 in·lbf}
07-11
6.85—9.80 N·m
{70.0—99.9 kgf·cm,
60.8—86.7 in·lbf}
acxuuw00002231
6. Install in the reverse order of removal. (See 07-11-20 Receiver/Drier Installation Note.)
7. Perform the refrigerant system performance test. (See 07-10-6 REFRIGERANT SYSTEM PERFORMANCE
TEST.)
acxuuw00000789
07-11–19
1871-1U-06B(07-11).fm 20 ページ 2006年3月15日 水曜日 午前11時30分
BASIC SYSTEM
Receiver/Drier Installation Note
1. Tighten the bolt of joint by hand.
2. Tighten the joint to the specified torque. FEMALE SIDE BLOCK
3. Connect the block joint type pipe by grasping the
female side of the block with hand holding firmly,
then tighten the connection bolt. MALE SIDE BLOCK
End Of Sie
WM: EVAPORATOR
acxuuw00000790
EVAPORATOR INSPECTION
id071100801500
1. Remove the A/C unit. (See 07-11-2 A/C UNIT REMOVAL/INSTALLATION.)
2. Remove the evaporator from the A/C unit.
3. Inspect for cracks, damage, and oil leakage.
• If any problems are found, replace the evaporator.
4. Inspect for bent fins.
• If any are bent, use a flathead screwdriver to straighten them.
End Of Sie
HEATER CORE INSPECTION
WM: HEATER CORE
id071100801600
1. Remove the A/C unit. (See 07-11-2 A/C UNIT REMOVAL/INSTALLATION.)
2. Remove the heater core from the A/C unit.
3. Inspect for cracks, damage, and coolant leakage.
• If any problems are found, replace the heater core.
4. Inspect for bent fins.
• If any are bent, use a flathead screwdriver to straighten them.
5. Verify that the heater core inlet and outlet pipe are not distorted or damaged.
• Repair with pliers if necessary.
End Of Sie
07-11–20
1871-1U-06B(07-40).fm 1 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
07-40 CONTROL SYSTEM
CONTROL SYSTEM Manual Air Conditioner . . . . . . . . . . . . . 07-40–12
LOCATION INDEX. . . . . . . . . . . . . . . . . 07-40–2 Wire Disassembly Note . . . . . . . . . . . . . 07-40–12
POWER METAL OXIDE Wire Assembly Note . . . . . . . . . . . . . . . 07-40–12
SEMICONDUCTOR FIELD CLIMATE CONTROL UNIT WIRE
EFFECT TRANSISTOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 07-40–12
(POWER MOS FET) Air Mix Wire. . . . . . . . . . . . . . . . . . . . . . 07-40–12
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–4 CLIMATE CONTROL UNIT INSPECTION
POWER METAL OXIDE [FULL-AUTO AIR CONDITIONER] . . . . 07-40–13
SEMICONDUCTOR FIELD EFFECT Terminal Voltage Table (Reference) . . . 07-40–13
TRANSISTOR (POWER MOS FET) CLIMATE CONTROL UNIT INSPECTION
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–5 [MANUAL AIR CONDITIONER] . . . . . . . 07-40–16
MAGNETIC CLUTCH Terminal Voltage Table (Reference) . . . 07-40–16
DISASSEMBLY/ASSEMBLY . . . . . . . . . 07-40–5 AIR MIX ACTUATOR
Bolt Removal/Installation Note . . . . . . . 07-40–5 REMOVAL/INSTALLATION . . . . . . . . . . 07-40–19
Stator and Thermal Protector AIR MIX ACTUATOR INSPECTION . . . . . 07-40–21
Removal Note . . . . . . . . . . . . . . . . . . 07-40–5 REFRIGERANT PRESSURE SWITCH
Stator and Thermal Protector REMOVAL/INSTALLATION . . . . . . . . . . 07-40–21
Installation Note . . . . . . . . . . . . . . . . . 07-40–6 Refrigerant Pressure Switch
Screw Installation Note . . . . . . . . . . . . 07-40–6 Installation Note . . . . . . . . . . . . . . . . . 07-40–21
Clamp Installation Note . . . . . . . . . . . . 07-40–6 REFRIGERANT PRESSURE SWITCH
Snap Ring Installation Note . . . . . . . . . 07-40–6 INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–22 07-40
MAGNETIC CLUTCH SOLAR RADIATION SENSOR
ADJUSTMENT . . . . . . . . . . . . . . . . . . . 07-40–6 REMOVAL/INSTALLATION . . . . . . . . . . 07-40–22
MAGNETIC CLUTCH INSPECTION . . . . 07-40–7 SOLAR RADIATION SENSOR
RESISTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–23
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–7 PASSENGER COMPARTMENT
RESISTOR INSPECTION . . . . . . . . . . . . 07-40–7 TEMPERATURE SENSOR
BLOWER MOTOR REMOVAL/INSTALLATION . . . . . . . . . . 07-40–23
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–8 PASSENGER COMPARTMENT
BLOWER MOTOR INSPECTION . . . . . . 07-40–8 TEMPERATURE SENSOR
EVAPORATOR TEMPERATURE INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–23
SENSOR AMBIENT TEMPERATURE SENSOR
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–8 REMOVAL/INSTALLATION . . . . . . . . . . 07-40–24
EVAPORATOR TEMPERATURE AMBIENT TEMPERATURE SENSOR
SENSOR INSPECTION . . . . . . . . . . . . . 07-40–9 INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–24
AIR INTAKE ACTUATOR CLIMATE CONTROL UNIT
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–9 REMOVAL/INSTALLATION
AIR INTAKE ACTUATOR [FULL-AUTO AIR CONDITIONER] . . . . 07-40–25
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–10 CLIMATE CONTROL UNIT REMOVAL
AIRFLOW MODE ACTUATOR [MANUAL AIR CONDITIONER] . . . . . . . 07-40–25
REMOVAL/INSTALLATION. . . . . . . . . . 07-40–10 CLIMATE CONTROL UNIT
AIRFLOW MODE ACTUATOR INSTALLATION
INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–11 [MANUAL AIR CONDITIONER] . . . . . . . 07-40–26
CLIMATE CONTROL UNIT AIRFLOW VOLUME CONTROL DIAL
DISASSEMBLY/ASSEMBLY . . . . . . . . . 07-40–11 INSPECTION . . . . . . . . . . . . . . . . . . . . . 07-40–26
Full-auto Air Conditioner . . . . . . . . . . . 07-40–11
End of Toc
WM: HVAC CONTROL SYSTEM
07-40–1
1871-1U-06B(07-40).fm 2 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
CONTROL SYSTEM LOCATION INDEX
id074000800100
2 1
12
18 16
19
17
15 8
10
FRONT
7
4
11
14
13
acxuuw00002307
07-40–2
1871-1U-06B(07-40).fm 3 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
1
12
18
16
19
15 17
FRONT
07-40
4
5
11
14
13
acxuuw00002308
07-40–3
1871-1U-06B(07-40).fm 4 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
10 Passenger compartment temperature sensor (full- 14 A/C relay
auto air conditioner) (See 09-21-4 RELAY INSPECTION.)
(See 07-40-23 PASSENGER COMPARTMENT 15 Blower relay
TEMPERATURE SENSOR REMOVAL/ (See 09-21-4 RELAY INSPECTION.)
INSTALLATION.)
(See 07-40-23 PASSENGER COMPARTMENT 16 PCM
TEMPERATURE SENSOR INSPECTION.) (See 01-40-6 PCM REMOVAL/INSTALLATION[L3
WITH TC].)
11 Evaporator temperature sensor (See 01-40-6 PCM INSPECTION[L3 WITH TC].)
(See 07-40-8 EVAPORATOR TEMPERATURE
SENSOR REMOVAL/INSTALLATION.) 17 BCM
(See 07-40-9 EVAPORATOR TEMPERATURE (See 09-40-1 BODY CONTROL MODULE (BCM)
SENSOR INSPECTION.) REMOVAL/INSTALLATION.)
(See 09-40-2 BODY CONTROL MODULE (BCM)
12 Refrigerant pressure switch INSPECTION.)
(See 07-40-21 REFRIGERANT PRESSURE
SWITCH REMOVAL/INSTALLATION.) 18 Rear window defroster relay
(See 07-40-22 REFRIGERANT PRESSURE (See 09-21-4 RELAY INSPECTION.)
SWITCH INSPECTION.) 19 TNS relay
13 Climate control unit (See 09-21-4 RELAY INSPECTION.)
(See 07-40-25 CLIMATE CONTROL UNIT
REMOVAL/INSTALLATION [FULL-AUTO AIR
CONDITIONER].)
(See 07-40-25 CLIMATE CONTROL UNIT
REMOVAL [MANUAL AIR CONDITIONER].)
(See 07-40-26 CLIMATE CONTROL UNIT
INSTALLATION [MANUAL AIR CONDITIONER].)
(See 07-40-11 CLIMATE CONTROL UNIT
DISASSEMBLY/ASSEMBLY.)
(See 07-40-12 CLIMATE CONTROL UNIT WIRE
ADJUSTMENT.)
(See 07-40-13 CLIMATE CONTROL UNIT
INSPECTION [FULL-AUTO AIR CONDITIONER].)
(See 07-40-16 CLIMATE CONTROL UNIT
INSPECTION [MANUAL AIR CONDITIONER].)
(See 07-40-26 AIRFLOW VOLUME CONTROL
DIAL INSPECTION.)
End Of Sie
POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR (POWER MOS FET) REMOVAL/
WM: POWER MOS FET
INSTALLATION
id074000800200
1. Disconnect the negative battery cable.
2. Remove the glove compartment. (See 09-17-8 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
1
1 Power MOS FET connector
2 Power MOS FET
acxuuw00000716
07-40–4
1871-1U-06B(07-40).fm 5 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR (POWER MOS FET) INSPECTION
id074000800300
1. Verify that the resistance between the terminals of
the power MOS FET is as shown in the table.
• If there is any malfunction, replace the power
MOS FET. B
1 KILOHM
E * A
Tester lead B
Resistance (kilohm) * *
+ − E
A B ∞ 2.2 KILOHMS
A E 6.9 A
B A Continuity 4.7 KILOHMS
B E Continuity
E A 6.9 acxuuw00000717
E B ∞
End Of Sie
MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY
WM: MAGNETIC CLUTCH
id074000800400
1. Disassemble in the order indicated in the table.
A
1 Bolt
(See 07-40-5 Bolt Removal/Installation Note.) 4
2 Pressure plate 2
3 07-40
3 Shim
4 Snap ring 5
1 15 {1.5, 11}
(See 07-40-6 Snap Ring Installation Note.)
5 A/C compressor pulley
6 Screw
(See 07-40-6 Screw Installation Note.)
7 Clamp
6
(See 07-40-6 Clamp Installation Note.)
8 Screw 7
(See 07-40-6 Screw Installation Note.)
9 Stator and thermal protector
(See 07-40-5 Stator and Thermal Protector
Removal Note.)
(See 07-40-6 Stator and Thermal Protector 8 10
Installation Note.)
10 A/C compressor body
9
2. Assemble in the reverse order of disassembly. A N·m {kgf·m, ft·lbf}
3. Adjust the magnetic clutch clearance. (See 07-40- acxuuw00000778
6 MAGNETIC CLUTCH ADJUSTMENT.)
acxuuw00002309
07-40–5
1871-1U-06B(07-40).fm 6 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
Stator and Thermal Protector Installation Note
1. Apply approx. 1 g {0.04 oz} of silicone (Shin-Etsu
Silicone KE-347W or similar) to the contact SILICONE
surface of the thermal protector, then thoroughly
install it onto the A/C compressor, leaving no SEALANT
gaps.
acxuuw00002310
SHAFT
acxuuw00002311
PRESSURE PLATE
acxuuw00001569
End Of Sie
acxuuw00001570
07-40–6
1871-1U-06B(07-40).fm 7 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
MAGNETIC CLUTCH INSPECTION
id074000800600
1. Connect battery positive voltage to terminal A of
magnetic clutch and ground to A/C compressor
body.
- +
A6E8540W015
07-40
A6E8540W016
RESISTOR REMOVAL/INSTALLATION
id074000800700
1. Disconnect the negative battery cable.
2. Remove the glove compartment. (See 07-40-7 RESISTOR REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
1
1 Resistor connector
2 Resistor
acxuuw00000718
RESISTOR INSPECTION
id074000800800
1. Verify that the resistance between the terminals of
the resistor is as shown in the table.
• If not as specified, replace the resistor.
Terminal Resistance (ohm) 0.65 OHM D C B A
0.22 OHM 1.89 OHMS
A— D 0.22
A— B 0.87
A— C 2.76
A D B C
End Of Sie
WM: BLOWER MOTOR
acxuuw00000977
07-40–7
1871-1U-06B(07-40).fm 8 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
BLOWER MOTOR REMOVAL/INSTALLATION
id074000800900
1. Disconnect the negative battery cable.
2. Remove the dashboard under cover (passenger’s side).
3. Remove in the order indicated in the table.
1 Blower motor connector
2 Blower motor
acxuuw00000720
M
A
acxuuw00000721
07-40–8
1871-1U-06B(07-40).fm 9 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
EVAPORATOR TEMPERATURE SENSOR INSPECTION
id074000801200
1. Set the fan speed MAX HI.
2. Set the temperature control at MAX COLD (Turn the left).
3. Turn the A/C switch off.
4. Set the RECIRCULATE mode.
5. Close all doors and windows.
6. Wait for 5 min.
7. Remove the glove compartment. (See 09-17-8 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
8. Disconnect the evaporator temperature sensor connector.
9. Measure the temperature at the blower inlet.
10. Measure the resistance between terminals of the KILOHM
evaporator temperature sensor.
• If the resistance is not as shown in the graph, 16
replace the evaporator temperature sensor.
End Of Sie
WM: AIR INTAKE ACTUATOR
14
12
RESISTANCE
10
8
07-40
6
0
-10 0 10 20 30 40 50 C { F}
{14} {32} {50} {68} {86} {104} {122}
TEMPERATURE
acxuuw00000978
1
2
acxuuw00001566
07-40–9
1871-1U-06B(07-40).fm 10 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
AIR INTAKE ACTUATOR INSPECTION
id074000801500
1. Connect battery positive voltage to terminal D or F and ground to terminal F or D of the air intake actuator.
2. Verify that the air intake actuator operates as
shown below. FRESH 90°
• If there is any malfunction, replace the air
intake actuator. RECIRCULATE
Connection F * D *
Movement 30° * *
B+ GND
D F RECIRCULATE → FRESH
F D FRESH → RECIRCULATE
acxuuw00001168
End Of Sie
WM: AIRFLOW MODE ACTUATOR
M D
acxuuw00002306
acxuuw00001568
07-40–10
1871-1U-06B(07-40).fm 11 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
AIRFLOW MODE ACTUATOR INSPECTION
id074000801700
Caution
• If the lever position exceeds the operation range shown in the figure, the circuit in the actuator
could be damaged. Always perform an actuator operation inspection with the lever movement
within the range shown in the figure.
1. Connect battery positive voltage to terminal D or F and ground to terminal F or D of the airflow mode actuator.
2. Verify that the airflow mode actuator operates as
shown below. VENT
• If there is any malfunction, replace the airflow 18.5°
mode actuator.
Connection F * D C B A
Movement
B+ GND
D F DEFROSTER → VENT 71.5°
F D VENT → DEFROSTER
DEFROSTER
acxuuw00000725
acxuuw00000726
End Of Sie
WM: CLIMATE CONTROL UNIT
BETWEEN B BETWEEN C
AND C AND A
KILOHM TERMINALS WIRE TERMINALS WIRE
3.5
RESISTANCE
0.5
INSTALLATION
2
1
acxuuw00001839
07-40–11
1871-1U-06B(07-40).fm 12 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
Manual Air Conditioner
Disassemble in the order indicated in the table. MANUAL AIR CONDITIONER
4 4
1 Knob
2 Air mix wire 3
(See 07-40-12 Wire Disassembly Note.)
(See 07-40-12 Wire Assembly Note.)
2
3 Airflow volume control dial
4 Illumination bulb
5 Body
5
1
acxuuw00000732
WIRE
1
CLIMATE CONTROL
UNIT
acxuuw00000733
acxuuw00000734
acxuuw00001840
07-40–12
1871-1U-06B(07-40).fm 13 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
CLIMATE CONTROL UNIT INSPECTION [FULL-AUTO AIR CONDITIONER]
id074000803400
1. Remove the climate control unit. (See 07-40-25 CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-
AUTO AIR CONDITIONER].)
2. Install the audio unit. (See 09-20-4 AUDIO UNIT REMOVAL/INSTALLATION.)
3. Connect the climate control unit connector.
4. Connect the negative (-) lead of the tester to body ground.
5. Turn the ignition switch to the ON position.
6. By inserting the positive (+) lead of the tester into each climate control unit terminal, measure the voltage
according to the terminal voltage table.
• If there is any malfunction, inspect the parts under “Inspection item (s)”.
— If the parts under “Inspection item (s)” are found to be normal (except for terminal T), replace the
climate control unit.
— For terminal T, first try replacing the power MOS FET. If there is still any malfunction, replace the
climate control unit.
W U S Q O M K I G E C A
X V T R P N L J H F D B
07-40
acxuuw00000985
07-40–13
1871-1U-06B(07-40).fm 14 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
Term Signal Measurement
Connected to Voltage (V) Inspection item (s)
inal name condition
• Wiring harness: continuity, short circuit
Rear window defroster (Climate control unit— rear window
Rear B+
switch OFF defroster relay: G— E)
window Rear window • Rear window defroster relay
G
defroster defroster relay
switch • Climate control unit: terminal voltage (D,
Rear window defroster
0.06 M)
switch ON
• Climate control unit
• Wiring harness: continuity (Climate
control unit—passenger compartment
temperature sensor: H—B, C—A)
Passenger Compared with
• Wiring harness: short circuit (Climate
compartmen Passenger temperature detected
Refer to control unit—passenger compartment
H t compartment by passenger
graph 2 temperature sensor: H—B)
temperature temperature sensor compartment
• Passenger compartment temperature
sensor input temperature sensor
sensor
• Climate control unit: terminal voltage (D,
M)
Moving towards • Wiring harness: continuity, short circuit
10.75
Motor RECIRCULATE (Climate control unit— air intake
I Air intake actuator actuator: I— F, K— D)
operation Moving towards
FRESH
0.72 • Air intake actuator
• Wiring harness: short circuit (Climate
control unit—air mix actuator, airflow
mode actuator, Solar radiation sensor:
• Air mix actuator J—A, B, A)
• Airflow mode IG SW ON 5.11 • Air mix actuator
J +5V actuator • Airflow mode actuator
• Solar radiation • Solar radiation sensor
sensor • Climate control unit: terminal voltage (D,
M)
IG SW OFF 0.01 • Climate control unit replacement
Moving towards • Wiring harness: continuity, short circuit
10.89
Motor FRESH (Climate control unit— air intake
K Air intake actuator actuator: K— D, I— F)
operation Moving towards
RECIRCULATE
0.72 • Air intake actuator
• Wiring harness: continuity (Climate
control unit—ambient temperature
sensor: C—A, L—B)
Compared with
Ambient • Wiring harness: short circuit (Climate
Ambient temperature detected Refer to
L temperature control unit—ambient temperature
temperature sensor by ambient graph 1
sensor input sensor: L—B)
temperature sensor
• Ambient temperature sensor
• Climate control unit: terminal voltage (D,
M)
• Wiring harness: continuity, short circuit
(Climate control unit— fuse: M— A/C
IG SW ON B+
10 A)
M IG2 A/C 10 A fuse • A/C 10 A fuse
• Wiring harness: continuity, short circuit
IG SW OFF 1.0 or less (Climate control unit— fuse: M— A/C
10 A)
Set temperature at • Wiring harness: continuity, short circuit
0.72
MAX COLD (Climate control unit— air mix actuator:
Potentiomet
N Air mix actuator N— C)
er input Set temperature at
4.42 • Air mix actuator
MAX HOT • Climate control unit: terminal voltage (J)
Moving towards VENT 10.39 • Wiring harness: continuity, short circuit
Motor Airflow mode (Climate control unit— airflow mode
O Moving towards
operation actuator 0.74 actuator: O— D, Q— F)
DEFROSTER • Airflow mode actuator
07-40–14
1871-1U-06B(07-40).fm 15 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
Term Signal Measurement
Connected to Voltage (V) Inspection item (s)
inal name condition
VENT 4.41 • Wiring harness: continuity, short circuit
BILEVEL 3.54 (Climate control unit— airflow mode
Potentiomet Airflow mode actuator: P— C)
P HEAT 2.60 • Airflow mode actuator
er input actuator
HEAT/DEF 1.69 • Climate control unit: terminal voltage (J)
DEFROSTER 0.74
Moving towards • Wiring harness: continuity, short circuit
9.98
Motor Airflow mode DEFROSTER (Climate control unit— airflow mode
Q
operation actuator actuator: Q— F, O— D)
Moving towards VENT 0.70 • Airflow mode actuator
• Wiring harness: continuity, short circuit
(Climate control unit— fuse: R—
R B+ ROOM 15 A fuse Under any condition B+
ROOM 15 A)
• ROOM 15 A fuse
Moving towards HOT 10.91 • Wiring harness: continuity, short circuit
Motor (Climate control unit— air mix actuator:
S Air mix actuator
operation Moving towards COLD 0.70 S— F, U— D)
• Air mix actuator
Fan stopped 11.84 1. Wiring harness: continuity, short circuit
Fan: manual LO 7.29 (Climate control unit— blower motor:
T— A) (Climate control unit— power
MOS FET: T— B, V— E) (Blower 07-40
motor— blower relay: B— A) (Blower
relay— fuse: D— BLOWER 40 A)
Blower • Blower motor 2. Wiring harness: continuity (Power MOS
T motor feed • Power MOS FET— body ground: A— GND) (Blower
back FET Fan: manual HI 0.20 relay— ground: A— GND)
3. Power MOS FET
4. Blower motor
5. Blower relay
6. BLOWER 40 A fuse
7. A/C 10 A fuse
8. Power MOS FET replacement
Moving towards COLD 10.96 • Wiring harness: continuity, short circuit
Motor (Climate control unit— air mix actuator:
U Air mix actuator
operation Moving towards HOT 0.70 U— D, S— F)
• Air mix actuator
Blower fan Fan stopped 0.07 1. Climate control unit: terminal voltage (T)
V speed Power MOS FET Fan: manual LO 3.10
control Fan: manual HI 7.23
• Wiring harness: short circuit (Climate
control unit— TNS relay: W— C)
Headlight switch OFF 1.0 or less
• TNS relay
• Headlight switch
W TNS signal TNS relay • Wiring harness: continuity, short circuit
(Climate control unit— TNS relay: W—
Headlight switch ON B+ C)
• TNS relay
• Headlight switch
• Wiring harness: continuity (Climate
Headlight switch ON control unit— instrument cluster: X—
and panel light control 0.31 2H) (Instrument cluster— body ground:
Illumination switch at max 2A— GND)
X Instrument cluster • Instrument cluster
control
Headlight switch ON • Wiring harness: short circuit (Climate
and panel light control 9.56 control unit— instrument cluster: X—
switch at min 2H)
07-40–15
1871-1U-06B(07-40).fm 16 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
Graph 1 (Ambient temperature sensor) Graph 2 (Passenger compartment temperature sensor)
5 5
4 4
VOLTAGE(V)
VOLTAGE(V)
3 3
2 2
1 1
0 0
-20 -10 0 10 20 30 40 50 -20 -10 0 10 20 30 40 50
{-4} {14} {32} {50} {68} {86} {104} {122} {-4} {14} {32} {50} {68} {86} {104} {122}
TEMPERATURE C { F} TEMPERATURE C { F}
4
VOLTAGE(V)
0
-20 -10 0 10 20 30 40 50
{-4} {14} {32} {50} {68} {86} {104} {122}
TEMPERATURE C { F}
End Of Sie
CLIMATE CONTROL UNIT INSPECTION [MANUAL AIR CONDITIONER]
id074000803500
1. Remove the climate control unit. (See 07-40-25 CLIMATE CONTROL UNIT REMOVAL [MANUAL AIR
CONDITIONER].)
2. Disconnect the air mix wire from the climate control unit
3. Install the audio unit. (See 09-20-4 AUDIO UNIT REMOVAL/INSTALLATION.)
4. Connect the climate control unit connector.
5. Connect the negative (-) lead of the tester to body ground.
6. Turn the ignition switch to the ON position.
7. By inserting the positive (+) lead of the tester into each climate control unit terminal, measure the voltage
according to the terminal voltage table.
• If there is any malfunction, inspect the parts under “Inspection item (s)”.
— If the parts under “Inspection item (s)” are found to be normal, replace the climate control unit.
W U S Q O M K I G E C A
X V T R P N L J H F D B
acxuuw00000989
07-40–16
1871-1U-06B(07-40).fm 17 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
Term Signal Measurement
Connected to Voltage (V) Inspection item (s)
inal name condition
• Wiring harness: continuity (Climate
Headlight switch ON control unit— instrument cluster: A—
and panel light control 0.45 2H) (Instrument cluster— body ground:
Illumination switch at max 2A— GND)
A Instrument cluster • Instrument cluster
control
Headlight switch ON • Wiring harness: short circuit (Climate
and panel light control 9.96 control unit— instrument cluster: A—
switch at min 2H)
• Wiring harness: short circuit (Climate
control unit— TNS relay: B— C)
Headlight switch OFF 1.0 or less
• TNS relay
• Headlight switch
B TNS signal TNS relay • Wiring harness: continuity, short circuit
(Climate control unit— TNS relay: B—
Headlight switch ON B+ C)
• TNS relay
• Headlight switch
C — — — — —
D — — — — —
• Wiring harness: short circuit (Climate
control unit—airflow mode actuator: E—
B) 07-40
Airflow mode IG SW ON 4.91
E +5V • Airflow mode actuator
actuator • Climate control unit: terminal voltage (R,
L)
IG SW OFF 1.0 or less • Climate control unit replacement
• Wiring harness: (Climate control unit—
Airflow volume control
0.06 airflow volume control dial: F— C)
dial ON
• Airflow volume control dial
FAN ON/ Airflow volume • Wiring harness: continuity (Climate
F control unit— airflow volume control
OFF control dial
Airflow volume control dial: F— C)
12.18
dial OFF • Climate control unit: terminal voltage
(R)
• Airflow volume control dial
VENT 4.20 • Wiring harness: continuity, short circuit
BILEVEL 3.34 (Climate control unit— airflow mode
Potentiomet Airflow mode actuator: G— C)
G HEAT 2.44 • Airflow mode actuator
er input actuator
HEAT/DEF 1.56 • Climate control unit: terminal voltage (E)
DEFROSTER 0.68
• Wiring harness: continuity, short circuit
Rear window defroster (Climate control unit— rear window
Rear B+
switch OFF defroster relay: H— E)
window Rear window • Rear window defroster relay
H
defroster defroster relay
switch • Climate control unit: terminal voltage (L,
Rear window defroster
0.06 R)
switch ON
• Climate control unit:
• Wiring harness: continuity (Climate
control unit—evaporator temperature
sensor: I—B, K—A)
Compared with
Evaporator • Wiring harness: short circuit (Climate
Evaporator temperature detected Refer to
I temperature control unit—evaporator temperature
temperature sensor by evaporator graph 2
sensor input sensor: I—B)
temperature sensor
• Evaporator temperature sensor
• Climate control unit: terminal voltage (L,
R)
A/C switch ON, airflow • Wiring harness: continuity (Climate
volume control dial at 0.03 control unit— BCM: J— 3V)
J A/C BCM 1st • BCM
• Wiring harness: continuity, short circuit
A/C switch OFF 5.02
(Climate control unit— BCM: J— 3V)
07-40–17
1871-1U-06B(07-40).fm 18 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
Term Signal Measurement
Connected to Voltage (V) Inspection item (s)
inal name condition
• Evaporator • Climate control unit: terminal voltage (L)
temperature
sensor
• Ambient
K Sensor GND Under any condition 1.0 or less
temperature
sensor
• Airflow mode
actuator
• Wiring harness: continuity (Climate
L GND Body ground Under any condition 1.0 or less
control unit— GND: L— GND)
M — — — — —
N — — — — —
O — — — — —
• Wiring harness: continuity, short circuit
(Climate control unit— fuse: P—
P B+ ROOM 15 A fuse Under any condition B+
ROOM 15 A)
• ROOM 15 A fuse
Moving towards • Wiring harness: continuity, short circuit
10.60
Motor Airflow mode DEFROSTER (Climate control unit— airflow mode
Q
operation actuator actuator: Q— F, S— D)
Moving towards VENT 0.69 • Airflow mode actuator
• Wiring harness: continuity, short circuit
(Climate control unit— fuse: R— A/C
IG SW ON B+
10 A)
R IG2 A/C 10 A fuse • A/C 10 A fuse
• Wiring harness: continuity, short circuit
IG SW OFF 1.0 or less (Climate control unit— fuse: R— A/C
10 A)
Moving towards VENT 10.64 • Wiring harness: continuity, short circuit
Motor Airflow mode (Climate control unit— airflow mode
S Moving towards
operation actuator 0.68 actuator: S— D, Q— F)
DEFROSTER • Airflow mode actuator
T — — — — —
U — — — — —
Moving towards • Wiring harness: continuity, short circuit
10.62
Motor RECIRCULATE (Climate control unit— air intake
V Air intake actuator actuator: V— F, X— D)
operation Moving towards
FRESH
0.66 • Air intake actuator
• Wiring harness: continuity (Climate
control unit—ambient temperature
sensor: W—B, K—A)
Compared with
Ambient • Wiring harness: short circuit (Climate
Ambient temperature detected Refer to
W temperature control unit—ambient temperature
temperature sensor by ambient graph 1
sensor input sensor: W—B)
temperature sensor
• Ambient temperature sensor
• Climate control unit: terminal voltage (L,
R)
Moving towards • Wiring harness: continuity, short circuit
10.64
Motor FRESH (Climate control unit— air intake
X Air intake actuator actuator: X— D, V— F)
operation Moving towards
RECIRCULATE
0.67 • Air intake actuator
07-40–18
1871-1U-06B(07-40).fm 19 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
Graph 1 (Ambient temperature sensor) Graph 2 (Evaporetor temperature sensor)
5 5
4 4
VOLTAGE(V)
VOLTAGE(V)
3 3
2 2
1 1
0 0
-20 -10 0 10 20 30 40 50 -20 -10 0 10 20 30 40 50
{-4} {14} {32} {50} {68} {86} {104} {122} {-4} {14} {32} {50} {68} {86} {104} {122}
TEMPERATURE C { F} TEMPERATURE C { F}
End Of Sie
AIR MIX ACTUATOR REMOVAL/INSTALLATION
WM: AIR MIX ACTUATOR
id074000802400
1. Disconnect the negative battery cable.
2. Remove the following parts: 07-40
(1) Console panel (See 09-17-15 CONSOLE PANEL REMOVAL/INSTALLATION.)
(2) Console (See 09-17-13 CONSOLE REMOVAL/INSTALLATION.)
(3) Front scuff plate inner (See 09-17-19 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(4) Front side trim (See 09-17-18 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
(5) Dashboard under cover
(6) Glove compartment (See 09-17-8 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
(7) Hood release lever (See 09-14-25 HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION.)
(8) Lower panel (See 09-17-9 LOWER PANEL REMOVAL/INSTALLATION.)
(9) Center panel (See 09-17-8 CENTER PANEL REMOVAL/INSTALLATION.)
(10)Audio unit (See 09-20-4 AUDIO UNIT REMOVAL/INSTALLATION.)
(11)Climate control unit (See 07-40-25 CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO
AIR CONDITIONER].) (See 07-40-25 CLIMATE CONTROL UNIT REMOVAL [MANUAL AIR
CONDITIONER].) (See 07-40-26 CLIMATE CONTROL UNIT INSTALLATION [MANUAL AIR
CONDITIONER].)
(12)Knee bolster (See 09-17-12 KNEE BOLSTER REMOVAL/INSTALLATION.)
(13)Meter hood (See 09-17-10 METER HOOD REMOVAL/INSTALLATION.)
(14)Column cover (See 09-17-8 COLUMN COVER REMOVAL/INSTALLATION.)
(15)Instrument cluster (See 09-22-2 INSTRUMENT CLUSTER REMOVAL/INSTALLATION.)
(16)Driver-side air bag module (See 08-10-6 DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
(17)Steering wheel (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(18)Combination switch (See 09-18-13 COMBINATION SWITCH REMOVAL/INSTALLATION.)
(19)Steering shaft (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
(20)A-pillar lower trim (See 09-17-16 A-PILLAR LOWER TRIM REMOVAL/INSTALLATION.)
(21)A-pillar trim (See 09-17-15 A-PILLAR TRIM REMOVAL/INSTALLATION.)
(22)Dashboard (See 09-17-4 DASHBOARD REMOVAL/INSTALLATION.)
3. Remove the blower motor. (See 07-40-8 BLOWER MOTOR REMOVAL/INSTALLATION.)
4. Remove the power MOS FET (Full-auto air conditioner) or resistor. (Manual air conditioner) (See 07-40-4
POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR (POWER MOS FET) REMOVAL/
INSTALLATION.) (See 07-40-7 RESISTOR REMOVAL/INSTALLATION.)
5. Remove the blower unit installation nuts.
6. Remove the screw securing the duct (2) to the A/C unit, by inserting a phillips screwdriver into the hole made
after removing the blower motor.
7. Remove the screw securing the duct (2) to the A/C unit.
07-40–19
1871-1U-06B(07-40).fm 20 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
8. Remove the duct (2).
INSTALLATION
HOLE OF THE
BLOWER MOTOR
DUCT (2)
SCREW
SCREW SCREW
acxuuw00000738
1
acxuuw00000739
07-40–20
1871-1U-06B(07-40).fm 21 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
AIR MIX ACTUATOR INSPECTION
id074000802500
Caution
• If the lever position exceeds the operation range shown in the figure, the circuit in the actuator
could be damaged. Always perform an actuator operation with the lever movement within the
range shown in the figure.
1. Connect battery positive voltage to terminal D or F and ground to terminal F or D of the air mix actuator.
2. Verify that the air mix actuator operates as shown
below.
• If there is any malfunction, replace the air mix MAX COLD
actuator. 22.5°
F * D C B A
Connection
Movement
B+ GND
D F HOT → COLD 67.5°
F D COLD → HOT
MAX HOT
acxuuw00001567
3. Verify that the resistance between the terminals of
the air mix actuator are as shown in the graph. F
• If there is any malfunction, replace the air mix
actuator. M 07-40
D
MAX HOT MAX COLD
B
C
A
acxuuw00000736
End Of Sie
WM: REFRIGERANT PRESSURE SWITCH
BETWEEN A BETWEEN C
AND C AND B
KILOHM
TERMINALS WIRE TERMINALS WIRE
3.5
RESISTANCE
0.5
07-40–21
1871-1U-06B(07-40).fm 22 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH INSPECTION
id074000802700
1. Install the manifold gauge.
2. Disconnect the refrigerant pressure switch connector.
3. Verify the high-pressure side reading of the HIGH AND LOW PRESSURE SWITCH
manifold gauge and continuity between the BETWEEN B AND C TERMINALS
terminals of the refrigerant pressure switch. 0.176—0.216 2.94—3.34
• If the continuity is not normal, replace the {1.795—2.202, 25.53—31.31} {30.0—34.0, 427—483}
refrigerant pressure switch. CONTINUITY
0.195—0.250
{1.989—2.549,
28.30—36.24}
NO CONTINUITY
MEDIUM-PRESSURE SWITCH
BETWEEN A AND D TERMINALS
1.08—1.38
{11.1—14.0, 158—199}
CONTINUITY
NO CONTINUITY
1.39—1.65
{14.2—16.8, 202—238}
MPa {kgf/cm2, psi}
E6U740ZWB105
End Of Sie
WM: SOLAR RADIATION SENSOR
D A
MEDIUM PRESSURE
CHU0740W024
SOLAR RADIATION SENSOR REMOVAL/INSTALLATION
id074000802800
1. Disconnect the negative battery cable.
2. Remove the dashboard under cover (driver’s side).
3. Press out the solar radiation sensor with its connector from under the instrument panel.
4. Remove in the order indicated in the table.
acxuuw00000982
CONTROL SYSTEM
SOLAR RADIATION SENSOR INSPECTION
End Of Sie
id074000802900
1. Shine a fluorescent light or expose the solar radiation sensor to natural sunlight.
2. Connect the positive (+) lead to terminal A and
the negative (−) lead to terminal B of the solar A
radiation sensor, and verify that the voltages are
as shown in the table.
• If the voltage is not as specified, replace the B
solar radiation sensor.
: Continuity
B A
Test condition Voltage (V) V
Sensor subject to fluorescent
light or natural sunlight 0.1—0.45
acxuuw00002540
Sensor covered by a cloth 0.1 or less
acxuuw00002541
End Of Sie
PASSENGER COMPARTMENT TEMPERATURE SENSOR REMOVAL/INSTALLATION
WM: CABIN TEMPERATURE SENSOR
id074000803000
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Front scuff plate inner (driver's side). (See 09-17-19 FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
(2) Front side trim (driver's side). (See 09-17-18 FRONT SIDE TRIM REMOVAL/INSTALLATION.)
(3) Console panel. (See 09-17-15 CONSOLE PANEL REMOVAL/INSTALLATION.) 07-40
(4) Console. (See 09-17-13 CONSOLE REMOVAL/INSTALLATION.)
(5) Hood release lever. (See 09-14-25 HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION.)
(6) Lower panel (See 09-17-9 LOWER PANEL REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
1 Air hose
2 Passenger compartment temperature sensor 3
connector 2
3 Passenger compartment temperature sensor
1
4. Install in the reverse order of removal.
End Of Sie
acxuuw00000745
PASSENGER COMPARTMENT TEMPERATURE SENSOR INSPECTION
id074000803100
1. Measure the temperature around the passenger compartment temperature sensor.
2. Measure the resistance between terminals of the KILOHM
passenger compartment temperature sensor. 20
• If the resistance is not as shown in the graph,
replace the passenger compartment 18
temperature sensor.
End Of Sie 16
WM: AMBIENT TEMPERATURE SENSOR
14
RESISTANCE
12
10
0
-10 0 10 20 30 40 50 °C {°F}
{14} {32} {50} {68} {86} {104} {122}
TEMPERATURE
A6E8540W021
07-40–23
1871-1U-06B(07-40).fm 24 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
AMBIENT TEMPERATURE SENSOR REMOVAL/INSTALLATION
id074000803200
1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Remove in the order indicated in the table.
1 Ambient temperature sensor connector
2 Ambient temperature sensor
2
acxuuw00000746
Note
• Ambient temperature sensor does not detect a sudden change in temperature sensitively caused by
driving or stopping the vehicle to stabilize the control of the full-auto air conditioner. Therefore, the
measured value may differ from the original value when the resistance of the ambient temperature sensor
is measured immediately after the removal.
1. After removing the ambient temperature sensor, leave it to the inspection place for 30 min or more.
2. Measure the temperature around the ambient temperature sensor.
3. Measure the resistance between terminals of the KILOHM
ambient temperature sensor.
• If the resistance is not as shown in the graph, 16
replace the ambient temperature sensor.
End Of Sie
SOKYU_WM: CLIMATE CONTROL UNIT
14
12
10
RESISTANCE
0
-10 0 10 20 30 40 50 C { F}
{14} {32} {50} {68} {86} {104} {122}
TEMPERATURE
acxuuw00000984
07-40–24
1871-1U-06B(07-40).fm 25 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER]
id074000809000
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Console (See 09-17-13 CONSOLE REMOVAL/INSTALLATION.)
(2) Lower panel (See 09-17-9 LOWER PANEL REMOVAL/INSTALLATION.)
(3) Center panel (See 09-17-8 CENTER PANEL REMOVAL/INSTALLATION.)
(4) Audio unit (See 09-20-4 AUDIO UNIT REMOVAL/INSTALLATION.)
3. Remove the screws and climate control unit.
4. Release the tab and pull the climate control unit
toward you.
5. Disconnect the climate control unit connectors
and remove the climate control unit.
6. Install in the reverse order of removal.
End Of Sie
CLIMATE
CONTROL
UNIT
CONNECTOR
TAB
07-40
CLIMATE CONTROL UNIT
acxuuw00001616
CLIMATE CONTROL UNIT REMOVAL [MANUAL AIR CONDITIONER]
id074000809100
1. Disconnect the negative battery cable.
2. Remove the following parts:
(1) Glove compartment. (See 09-17-8 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
(2) Console (See 09-17-13 CONSOLE REMOVAL/INSTALLATION.)
(3) Lower panel (See 09-17-9 LOWER PANEL REMOVAL/INSTALLATION.)
(4) Center panel (See 09-17-8 CENTER PANEL REMOVAL/INSTALLATION.)
(5) Audio unit (See 09-20-4 AUDIO UNIT
REMOVAL/INSTALLATION.)
3. Disconnect the air mix wire from wire clamp and
link.
4. Remove the screws and climate control unit.
5. Release the tab and pull the climate control unit WIRE CLAMP AND LINK
toward you.
acxuuw00001592
07-40–25
1871-1U-06B(07-40).fm 26 ページ 2006年3月16日 木曜日 午後4時1分
CONTROL SYSTEM
6. Disconnect the climate control unit connectors
and remove the climate control unit.
CLIMATE CONTROL UNIT CONNECTOR
End Of Sie
TAB
acxuuw00001617
CLIMATE CONTROL UNIT INSTALLATION [MANUAL AIR CONDITIONER]
id074000809200
1. Pass air mix wire through the following routes then connect to A/C unit. (Manual air conditioner)
acxuuw00001593
1
2
3
4 acxuuw00001889
acxuuw00001888
End Of Sie
07-40–26
1871-1U-06B(07-50).fm 1 ページ 2006年3月15日 水曜日 午前11時32分
TECHNICAL DATA
07-50 TECHNICAL DATA
HVAC TECHNICAL DATA . . . . . . . . . . . . 07-50–1
End of Toc
HVAC TECHNICAL DATA
WM: HEATER, VENTILATION AND AIR CONDITIONING (HVAC)
id075000800100
Item Specification
REFRIGERANT SYSTEM
Type R-134a
Refrigerant
Regular amount (approx. quantity) (g {oz}) 500 {17.7}
BASIC SYSTEM
Type ATMOS GU10
A/C compressor Lubrication oil Sealed volume
(approx. (ml {cc, fl oz}) 120 {120, 4.06}
quantity)
CONTROL SYSTEM
A/C compressor Magnetic clutch clearance (mm {in}) 0.3— 0.5 {0.012— 0.019}
End Of Sie
07-50
07-50–1
1871-1U-06B(07-60).fm 1 ページ 2006年3月15日 水曜日 午前11時32分
SERVICE TOOLS
07-60 SERVICE TOOLS
HVAC SST . . . . . . . . . . . . . . . . . . . . . . . . 07-60–1
End of Toc
HVAC SST
WM: HEATER, VENTILATION AND AIR CONDITIONING (HVAC)
id076000800100
End Of Sie
07-60
07-60–1
1871-1U-06B(08-02).fm 1 ページ 2006年3月15日 水曜日 午前11時33分
RESTRAINTS 08SECTION
Toc of SCT
ON-BOARD DIAGNOSTIC . . . . 08-02 AIR BAG SYSTEM . . . . . . . . . . 08-10
SYMPTOM SEAT BELT. . . . . . . . . . . . . . . . 08-11
TROUBLESHOOTING . . . . . . 08-03 SERVICE TOOLS . . . . . . . . . . . 08-60
Toc of SCT
08-02 ON-BOARD DIAGNOSTIC
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 08-02–1 DTC B1877, B1878, B1879, B1885. . . . . 08-02–18
Outline. . . . . . . . . . . . . . . . . . . . . . . . . . 08-02–1 DTC B1881, B1882, B1883, B1886. . . . . 08-02–20
FLOWCHART . . . . . . . . . . . . . . . . . . . . . . 08-02–2 DTC B1884, B1890 . . . . . . . . . . . . . . . . . 08-02–22
AIR BAG SYSTEM DTC B1913, B1916, B1932, B1934. . . . . 08-02–24
WIRING DIAGRAM. . . . . . . . . . . . . . . . . 08-02–3 DTC B1913, B1925, B1933, B1935. . . . . 08-02–27
DTC DISPLAY. . . . . . . . . . . . . . . . . . . . . . 08-02–4 DTC B1992, B1993, B1994, B1995. . . . . 08-02–29
CLEARING DTC . . . . . . . . . . . . . . . . . . . . 08-02–4 DTC B1996, B1997, B1998, B1999. . . . . 08-02–30
DTC TABLE . . . . . . . . . . . . . . . . . . . . . . . 08-02–4 DTC B2228, B2230, B2232, B2234. . . . . 08-02–32
PID/DATA MONITOR DISPLAY . . . . . . . . 08-02–8 DTC B2229, B2231, B2233, B2235. . . . . 08-02–35 08-02
PID/DATA MONITOR TABLE . . . . . . . . . . 08-02–8 DTC B2290 . . . . . . . . . . . . . . . . . . . . . . . 08-02–37
DTC B1013 . . . . . . . . . . . . . . . . . . . . . . . . 08-02–10 DTC B2296 . . . . . . . . . . . . . . . . . . . . . . . 08-02–38
DTC B1017 . . . . . . . . . . . . . . . . . . . . . . . . 08-02–11 DTC B2444, U2017 . . . . . . . . . . . . . . . . . 08-02–40
DTC B1144, B1145. . . . . . . . . . . . . . . . . . 08-02–12 DTC B2445, U2018 . . . . . . . . . . . . . . . . . 08-02–43
DTC B1146, B1147. . . . . . . . . . . . . . . . . . 08-02–14 DTC B2477 . . . . . . . . . . . . . . . . . . . . . . . 08-02–45
DTC B1231 . . . . . . . . . . . . . . . . . . . . . . . . 08-02–15 DTC B2773, B2774, B2775, B2776. . . . . 08-02–45
DTC B1317, B1318. . . . . . . . . . . . . . . . . . 08-02–16 DTC B2777, B2778, B2779, B2780. . . . . 08-02–47
DTC B1342 . . . . . . . . . . . . . . . . . . . . . . . . 08-02–17 DTC B2867 . . . . . . . . . . . . . . . . . . . . . . . 08-02–49
DTC B1868 . . . . . . . . . . . . . . . . . . . . . . . . 08-02–18 DTC C1947, C1948, C1981 . . . . . . . . . . . 08-02–50
End of Toc
FOREWORD
WM: AIR BAG SYSTEM
id080200800100
Outline
• The OBD (on-board diagnostic) system has the following functions:
— Malfunction detection function: Detects malfunctions in the air bag system and outputs DTCs.
— Data monitor function: Reads out specific input/output signals and the system status.
• Diagnostic DTCs can be read/cleared using the M-MDS.
Note
• When the air bag system is malfunctioning, turn the ignition switch to the ON position to display the
current DTC using the air bag system warning light on the instrument cluster. However this light is strictly
for reference. Make sure to inspect the system using the M-MDS.
End Of Sie
08-02–1
1871-1U-06B(08-02).fm 2 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
FLOWCHART
id080200800200
• Use the following flowchart to verify the cause of the trouble.
Note
• While performing the inspection of the past malfunction code, the applicable DTCs may be added to
memory by removing or disconnecting the related parts. Inspect only the DTCs that were indicated before
inspecting.
• When DTCs of the present malfunction are no longer output after present or past malfunctions or both
have been repaired, be sure to perform past malfunction display cancellation to prevent repair of
malfunctions that have already been repaired.
START
No
Using M-MDS, No
Past malfunction Yes
Using M-MDS, verify if a DTC has been verify if DTCs are present.
stored in SAS control module. Is DTC displayed?
Is DTC displayed?
Yes
No Yes
Note
For DTCs that are the same as DTCs displayed in past malfunction diagnosis, go to Yes.
For DTCs that are not displayed but were displayed in past malfunction diagnosis, go to No.
No
Past malfunction
Inspect all DTCs starting from the smallest code.
However, if inspection item for part that has already been repaired appears during
inspection, finish inspection for that DTC at that point in time.
Yes Using M-MDS, verify if a DTC has been stored in SAS control module.
Is DTC displayed?
No
END
acxuuw00001022
End Of Sie
08-02–2
1871-1U-06B(08-02).fm 3 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
AIR BAG SYSTEM WIRING DIAGRAM
id080200800300
IG1
INSTRUMENT CLOCK SPRING
CLUSTER
1V 1C 3A 1A
INFLATOR
1W NO.1
1S 1D 3B 1B DRIVER-SIDE
AIR BAG
2E 1A 4A 2A MODULE
CAN SYSTEM- 1J INFLATOR
RELATED MODULE 2F NO.2
1G 1B 4B 2B
TWISTED PAIR
SEAT TRACK A 2W 1P 1A
INFLATOR
POSITION
B 1M NO.1
SENSOR 2X 1B
PASSENGER-SIDE
IG1 AIR BAG MODULE
1D 2A
INFLATOR
INFORMATION 1A NO.2
1U 2B
DISPLAY
2S A DRIVER-SIDE
TWISTED
IG1 PRE-TENSIONER
PAIR 2P B
SEAT SEAT BELT
WEIGHT 1A
SENSOR SEAT 3A 2Y A DRIVER-SIDE
1B
(LH) WEIGHT CURTAIN AIR BAG
SENSOR 3D 1I 2V B MODULE
SEAT CONTROL
WEIGHT 2A MODULE
08-02
3B 2M A
SENSOR DRIVER-SIDE SIDE
2B
(RH) 2O AIR BAG MODULE
B
SAS
CONTROL 2J A PASSENGER-SIDE
TWISTED PAIR MODULE PRE-TENSIONER
CRASH ZONE A 1B 2G B SEAT BELT
SENSOR B 1C
2D A PASSENGER-SIDE
CURTAIN AIR BAG
A 2T 2A B MODULE
DRIVER-SIDE
BUCKLE SWITCH 2L PASSENGER-SIDE
B A
SIDE AIR BAG
A 2H 2I B MODULE
PASSENGER-SIDE
BUCKLE SWITCH TWISTED PAIR
B 1X
2Z A DRIVER-SIDE
SIDE AIR BAG
2AA B SENSOR NO.1
1a
POOR CONNECTION
DETECTOR BAR 1b 2B A PASSENGER-SIDE
SIDE AIR BAG
2C B SENSOR NO.1
2a
POOR CONNECTION
DETECTOR BAR 3W A DRIVER-SIDE
2b
SIDE AIR BAG
3X B SENSOR NO.2
3a
POOR CONNECTION 3T A PASSENGER-SIDE
DETECTOR BAR 3b SIDE AIR BAG
3U B SENSOR NO.2
1b 1a 2b 2a 3b 3a
1V 1S 1P 1M 1J 1G 1D 1A 2Y 2V 2S 2P 2M 2J 2G 2D 2A * * * * * * * *
1W 1T 1Q 1H 1E 1B 2Z 2W 2T 2H 2E 2B 3W 3T * *
1X 1U 1R 1I 1F 1C 2AA 2X 2U 2R 2O 2L 2I 2F 2C 3X 3U * * * *
acxuuw00001024
End Of Sie
08-02–3
1871-1U-06B(08-02).fm 4 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC DISPLAY
id080200800400
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (notebook PC)
— Select the “Toolbox” tab.
— Select “Self Test”.
— Select “Module”.
— Select “RCM”.
• When using the PDS (pocket PC)
— Select “Module Tests”.
— Select “RCM”.
DLC-2
— Select “Self Test”.
acxuuw00001023
3. Verify the DTC according to the directions on the
screen.
• If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
4. After completion of repairs, clear all DTCs stored in the SAS control module. (See 08-02-4 CLEARING DTC.)
End Of Sie
CLEARING DTC
id080200800500
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (notebook PC)
— Select the “Toolbox” tab.
— Select “Self Test”.
— Select “Module”.
— Select “RCM”.
• When using the PDS (pocket PC)
— Select “Module Tests”.
— Select “RCM”.
DLC-2
— Select “Self Test”.
acxuuw00001023
3. Verify the DTC according to the directions on the
screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.
End Of Sie
DTC TABLE
id080200800600
• DTCs are common for present and past malfunction diagnosis.
Note
• When DTCs not shown in the DTC table are displayed, replace the SAS control module.
• If the air bag system warning light does not illuminate or remains illuminated when the ignition switch is
turned to the ON position, inspect and repair the air bag system warning light circuit, and then confirm that
the air bag system warning light is operational.
• The air bag system warning light flashes the DTC pattern for five cycles, and then remains illuminated
until the ignition switch is turned to the ACC or LOCK position.
DTC
Air bag system warning light
M-MDS System malfunction location Page
display Priority
Flashing pattern
ranking
Seat weight sensor calibration (See 08-02-10
B1013 16 21
error DTC B1013)
08-02–4
1871-1U-06B(08-02).fm 5 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC
Air bag system warning light
M-MDS System malfunction location Page
display Priority
Flashing pattern
ranking
Passenger-side side air bag
B1146 sensor No.2 system internal
circuit disabled (See 08-02-14
46 10 DTC B1146,
Passenger-side side air bag B1147)
B1147 sensor No.2 system
communication error
SAS control module activation (See 08-02-15
B1231 13 3
(deployment) control freeze DTC B1231)
SAS control module power supply
Air bag system warning light is illuminated all
B1317 voltage increases (16.1 V or (See 08-02-16
the time
more) DTC B1317,
Air bag system warning light is illuminated all SAS control module power supply B1318)
B1318
the time voltage decreases (less than 8 V)
SAS control module (internal
12 2
circuit abnormal) (See 08-02-17
B1342
DTC B1342)
SAS control module (DTC 12
Continuously illuminated 1
detection circuit malfunction)
Air bag system warning light (See 08-02-18
B1868
malfunction DTC B1868)
Driver-side pre-tensioner seat belt 08-02
B1877
circuit resistance high (See 08-02-18
Driver-side pre-tensioner seat belt DTC B1877,
B1878 38 16
circuit short to power supply B1878, B1879,
Driver-side pre-tensioner seat belt B1885)
B1879
circuit short to body ground
Passenger-side pre-tensioner
B1881
seat belt circuit resistance high
Passenger-side pre-tensioner (See 08-02-20
B1882 seat belt circuit short to power DTC B1881,
39 15
supply B1882, B1883,
Passenger-side pre-tensioner B1886)
B1883 seat belt circuit short to body
ground
Passenger air bag deactivation (See 08-02-22
B1884 18 22 (PAD) indicator circuit open or DTC B1884,
short to body ground B1890)
(See 08-02-18
Driver-side pre-tensioner seat belt DTC B1877,
B1885 38 16
circuit resistance low B1878, B1879,
B1885)
(See 08-02-20
Passenger-side pre-tensioner DTC B1881,
B1886 39 15
seat belt circuit resistance low B1882, B1883,
B1886)
Passenger air bag deactivation (See 08-02-22
B1890 18 22 (PAD) indicator circuit short to DTC B1884,
power supply B1890)
(See 08-02-24
Driver-side air bag module
DTC B1913,
19 14 (inflator No.1) circuit short to body
B1916, B1932,
ground
B1934)
B1913
(See 08-02-27
Passenger-side air bag module
DTC B1913,
21 13 (inflator No.1) circuit short to body
B1925, B1933,
ground
B1935)
08-02–5
1871-1U-06B(08-02).fm 6 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC
Air bag system warning light
M-MDS System malfunction location Page
display Priority
Flashing pattern
ranking
(See 08-02-24
Driver-side air bag module
DTC B1913,
B1916 19 14 (inflator No.1) circuit short to
B1916, B1932,
power supply
B1934)
(See 08-02-27
Passenger-side air bag module
DTC B1913,
B1925 21 13 (inflator No.1) circuit short to
B1925, B1933,
power supply
B1935)
(See 08-02-24
Driver-side air bag module
DTC B1913,
B1932 19 14 (inflator No.1) circuit resistance
B1916, B1932,
high
B1934)
(See 08-02-27
Passenger-side air bag module
DTC B1913,
B1933 21 13 (inflator No.1) circuit resistance
B1925, B1933,
high
B1935)
(See 08-02-24
Driver-side air bag module
DTC B1913,
B1934 19 14 (inflator No.1) circuit resistance
B1916, B1932,
low
B1934)
(See 08-02-27
Passenger-side air bag module
DTC B1913,
B1935 21 13 (inflator No.1) circuit resistance
B1925, B1933,
low
B1935)
Driver-side side air bag module
B1992
circuit short to power supply
Driver-side side air bag module (See 08-02-29
B1993
circuit short to body ground DTC B1992,
22 18
Driver-side side air bag module B1993, B1994,
B1994 B1995)
circuit resistance high
Driver-side side air bag module
B1995
circuit resistance low
Passenger-side side air bag
B1996 module circuit short to power
supply
Passenger-side side air bag (See 08-02-30
B1997 module circuit short to body DTC B1996,
23 17 ground B1997, B1998,
Passenger-side side air bag B1999)
B1998
module circuit resistance high
Passenger-side side air bag
B1999
module circuit resistance low
(See 08-02-32
Driver-side air bag module
DTC B2228,
B2228 19 14 (inflator No.2) circuit short to body
B2230, B2232,
ground
B2234)
(See 08-02-35
Passenger-side air bag module
DTC B2229,
B2229 21 13 (inflator No.2) circuit short to body
B2231, B2233,
ground
B2235)
(See 08-02-32
Driver-side air bag module
DTC B2228,
B2230 19 14 (inflator No.2) circuit short to
B2230, B2232,
power supply
B2234)
(See 08-02-35
Passenger-side air bag module
DTC B2229,
B2231 21 13 (inflator No.2) circuit short to
B2231, B2233,
power supply
B2235)
08-02–6
1871-1U-06B(08-02).fm 7 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC
Air bag system warning light
M-MDS System malfunction location Page
display Priority
Flashing pattern
ranking
(See 08-02-32
Driver-side air bag module
DTC B2228,
B2232 19 14 (inflator No.2) circuit resistance
B2230, B2232,
high
B2234)
(See 08-02-35
Passenger-side air bag module
DTC B2229,
B2233 21 13 (inflator No.2) circuit resistance
B2231, B2233,
high
B2235)
(See 08-02-32
Driver-side air bag module
DTC B2228,
B2234 19 14 (inflator No.2) circuit resistance
B2230, B2232,
low
B2234)
(See 08-02-35
Passenger-side air bag module
DTC B2229,
B2235 21 13 (inflator No.2) circuit resistance
B2231, B2233,
low
B2235)
Seat weight sensor signal (See 08-02-37
B2290 16 21
malfunction DTC B2290)
Crash zone sensor
(See 08-02-38
B2296 42 9 (communication error, internal
DTC B2296)
circuit abnormal)
08-02
(See 08-02-40
Driver-side side air bag sensor
B2444 43 8 DTC B2444,
(internal circuit abnormal)
U2017)
(See 08-02-43
Passenger-side side air bag
B2445 44 7 DTC B2445,
sensor (internal circuit abnormal)
U2018)
(See 08-02-45
B2477 54 5 Configuration error
DTC B2477)
Driver-side curtain air bag module
B2773
circuit resistance low
Driver-side curtain air bag module (See 08-02-45
B2774
circuit resistance high DTC B2773,
24 20
Driver-side curtain air bag module B2774, B2775,
B2775 B2776)
circuit short to body ground
Driver-side curtain air bag module
B2776
circuit short to power supply
Passenger-side curtain air bag
B2777
module circuit resistance low
Passenger-side curtain air bag
B2778
module circuit resistance high (See 08-02-47
Passenger-side curtain air bag DTC B2777,
25 19
B2779 module circuit short to body B2778, B2779,
ground B2780)
Passenger-side curtain air bag
B2780 module circuit short to power
supply
Poor connection of any SAS (See 08-02-49
B2867 58 6
control module connectors DTC B2867)
Seat track position sensor circuit
C1947
short to body ground
(See 08-02-50
Seat track position sensor circuit
C1948 49 23 DTC C1947,
resistance not within specification
C1948, C1981)
Seat track position sensor circuit
C1981
open or short to power supply
08-02–7
1871-1U-06B(08-02).fm 8 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC
Air bag system warning light
M-MDS System malfunction location Page
display Priority
Flashing pattern
ranking
(See 08-02-40
Driver-side side air bag sensor
U2017 43 8 DTC B2444,
(communication error)
U2017)
(See 08-02-43
Passenger-side side air bag
U2018 44 7 DTC B2445,
sensor (communication error)
U2018)
U0073 CAN system communication error (See 09-02D-7
Communication error to SAS DTC
U0151 TABLE[MULTIPLE
14 12 control module
X
Communication error to COMMUNICATIO
U0155
instrument cluster N SYSTEM])
End Of Sie
PID/DATA MONITOR DISPLAY
id080200800700
1. Connect the M-MDS to the DLC-2 connector.
2. After the vehicle is identified, select the following
items from the initialization screen of the M-MDS.
• When using the IDS (notebook PC)
— Select the “Toolbox” tab.
— Select “DataLogger”.
— Select “Module”.
— Select “RCM”.
• When using the PDS (pocket PC)
— Select “Module Tests”.
— Select “RCM”.
DLC-2
— Select “DataLogger”.
acxuuw00001023
3. Select the applicable PID from the PID table.
4. Verify the PID data according to the directions on
the screen.
Note
• The PID data screen function is used for monitoring the calculated value. Therefore, if the monitored value
of the output parts is not within the specification, inspection of the monitored value of input parts
corresponding to applicable output part control is necessary. In addition, because the system does not
display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output
part individually.
End Of Sie
PID/DATA MONITOR TABLE
id080200800800
08-02–8
1871-1U-06B(08-02).fm 9 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
PID name (definition) Unit/Condition Operation Condition (Reference) Terminal
• Seat weight sensor calibration start-up: Starting
• Seat weight sensor calibration completed normally:
Normal End
Starting/ • Seat weight sensor calibration command being sent:
Normal End/ Commanding
Commanding/ • Voltage malfunction during seat weight sensor calibration:
OCS_CAL_ST*2 NG (Voltage)/ NG (Voltage)
(Seat weight sensor 1I
NG (Weight)/ • Weight error during seat weight sensor calibration: NG
calibration status) Timeout/ (Weight)
In Process/ • Seat weight sensor calibration time limit passed: Timeout
OCS Fault • Seat weight sensor calibration being processed: In
Process
• Seat weight sensor or Seat weight sensor control module
malfunction: OCS Fault
Empty/
SMALL/
OCS_SYS_ST*1 Indeterminate/
Occupant classification status determined by seat weight
1I
(Seat weight sensor status) sensor
LARGE/
Invalid
OCSFLT_CAL
OK/ • Sensor normal: OK
(Passenger sensing system 1I
FAULT • Seat weight sensor calibration error: FAULT
calibration status)
OCSFLT_COM • Sensor normal: OK
OK/
(Passenger sensing system • Seat weight sensor control module communication error: 1I
FAULT
communication status) FAULT
OCSFLT_L 08-02
OK/ • Sensor normal: OK
(Passenger sensing system 1I
FAULT • Seat weight sensor (LH) malfunction: FAULT
(LH) malfunction status)
OCSFLT_MDL
(Passenger sensing system OK/ • Sensor normal: OK
1I
control module malfunction FAULT • Seat weight sensor control module malfunction: FAULT
status)
OCSFLT_R
OK/ • Sensor normal: OK
(Passenger sensing system 1I
FAULT • Seat weight sensor (RH) malfunction: FAULT
(RH) malfunction status)
PS_WEIGHT
(Seat weight sensor measured kg Display of load (body weight) on passenger-side seat 1I
weight of passenger)
• Passenger-side air bag module non-operation (non-
PSAB_DepSt
Inactive/ deployment) status: Inactive
(Passenger-side air bag 1I
Active • Passenger-side air bag module operation (deployment)
module deployment status)
enabled status: Active
RES_AB_D
(Driver-side air bag module ohm Under any condition: 1.5— 4.4 ohms 1S, 1V
(inflator No.1) resistance)
RES_AB_P
(Passenger-side air bag
ohm Under any condition: 1.4— 3.6 ohms 1M, 1P
module (inflator No.1)
resistance)
RES_AB2_D
(Driver-side air bag module ohm Under any condition: 1.5— 4.4 ohms 1G, 1J
(inflator No.2) resistance)
RES_AB2_P
(Passenger-side air bag
ohm Under any condition: 1.4— 3.6 ohms 1A, 1D
module (inflator No.2)
resistance)
RES_CAB_D
(Driver-side curtain air bag ohm Under any condition: 1.4— 3.9 ohms 2V, 2Y
module resistance)
RES_CAB_P
(Passenger-side curtain air ohm Under any condition: 1.4— 3.9 ohms 2A, 2D
bag module resistance)
RES_PT_D
(Driver-side pre-tensioner seat ohm Under any condition: 1.5— 3.7 ohms 2P, 2S
belt resistance)
08-02–9
1871-1U-06B(08-02).fm 10 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
PID name (definition) Unit/Condition Operation Condition (Reference) Terminal
RES_PT_P
(Passenger-side pre-tensioner ohm Under any condition: 1.5— 3.7 ohms 2G, 2J
seat belt resistance)
RES_SAB_D
(Driver-side side air bag ohm Under any condition: 1.4— 3.9 ohms 2M, 2O
module resistance)
RES_SAB_P
(Passenger-side side air bag ohm Under any condition: 1.4— 3.9 ohms 2I, 2L
module resistance)
TRAK_SW
Forward/ • Front seat front position: Forward
(Seat track position sensor 2W, 2X
Rearward • Front seat rear position: Rearward
state)
*1
: Used during seat weight sensor calibration setting. Not necessary for diagnostic.
*2 : When the calibration error is displayed, the error can be cleared by turning the ignition switch to the LOCK
position.
End Of Sie
DTC B1013
id080200800900
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT SEAT WEIGHT SENSOR Yes [Present malfunction diagnosis]
• Properly install the passenger-side front • Replace the SAS control module.
seat. (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Inspect the seat weight sensor. (See 08-10- INSTALLATION.)
12 SEAT WEIGHT SENSOR [Past malfunction diagnosis]
CALIBRATION.) • DTC troubleshooting completed.
• Is the seat weight sensor normal?
No Go to the next step.
2 INSPECT PASSENGER-SIDE FRONT SEAT Yes Replace any deformed parts or remove any foreign
• Turn the ignition switch to the LOCK position. objects.
• Disconnect the negative battery cable and • After replacement, perform seat weight sensor
wait for 1 min or more. calibration and reperform the DTC inspection. If the
• Remove the passenger-side seat and DTC is displayed, go the next step. (See 08-10-12
visually inspect for the following: SEAT WEIGHT SENSOR CALIBRATION.)
— Seat under-bracket deformation No Go to the next step.
— Seat frame deformation
— Seat weight sensor deformation
— Foreign objects stuck in seat
• Are any of the parts deformed or are any
foreign objects stuck in the seat?
08-02–10
1871-1U-06B(08-02).fm 11 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
3 INSPECT FLOOR Yes Go to the next step.
• Visually inspect the installation parts of the No Repair floor deformation.
passenger-side seat for the following: • After repair, perform seat weight sensor calibration
— Abnormal floor deformation and reperform the DTC inspection. If the DTC is
— Installation hole of passenger-side seat is displayed even though the floor has been repaired, go
improperly positioned the next step. (See 08-10-12 SEAT WEIGHT
• Is the floor normal? SENSOR CALIBRATION.)
4 INSPECT SEAT WEIGHT SENSOR CONTROL Yes Replace the seat weight sensor control module.
MODULE (See 08-10-11 SEAT WEIGHT SENSOR CONTROL
• Replace the seat weight sensor. MODULE REMOVAL/INSTALLATION.)
• After replacement, perform seat weight • After replacement, perform seat weight sensor
sensor calibration. (See 08-10-12 SEAT calibration and reperform the DTC inspection. If the
WEIGHT SENSOR CALIBRATION.) DTC is displayed even though the seat weight sensor
• Reperform the DTC inspection. control module has been replaced, replace the SAS
• Is DTC B1013 indicated? control module. (See 08-10-10 SAS CONTROL
MODULE REMOVAL/INSTALLATION.)
No DTC troubleshooting completed.
End Of Sie
DTC B1017
id080200820000
Diagnostic procedure
STEP INSPECTION ACTION
1 CONFIGURATION Yes [Present malfunction diagnosis]
• Using the M-MDS perform SAS control • When only DTC B1017 is displayed:
module configuration. (See 08-10-11 SAS — Go to the next step.
CONTROL MODULE CONFIGURATION.) • When DTCs except B1017 are also displayed:
• Turn the ignition switch to the ON position. — Perform troubleshooting according to the
• Is DTC B1017 indicated? corresponding DTC inspection (except DTC
B1017).
[Past malfunction diagnosis]
• DTC troubleshooting completed.
No DTC troubleshooting completed.
2 INSPECT SAS CONTROL MODULE Yes [Present malfunction diagnosis]
• Using the M-MDS perform SAS control • Replace the SAS control module.
module configuration. (See 08-10-11 SAS (See 08-10-10 SAS CONTROL MODULE REMOVAL/
CONTROL MODULE CONFIGURATION.) INSTALLATION.)
• Turn the ignition switch to the ON position. [Past malfunction diagnosis]
• Is DTC B1017 indicated? • DTC troubleshooting completed.
No DTC troubleshooting completed.
End Of Sie
08-02–11
1871-1U-06B(08-02).fm 12 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B1144, B1145
id080200809800
B1144 Driver-side side air bag sensor No. 2 system internal circuit disabled
DTC
B1145 Driver-side side air bag sensor No. 2 system communication error
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.
• Malfunction in wiring harness between driver-side side air bag sensor No. 2 and SAS control module
• Malfunction in driver-side side air bag sensor No. 2 circuit
• Open or short circuit in wiring harness between driver-side side air bag sensor No. 2 and SAS control
POSSIBLE module
CAUSE • Driver-side side air bag sensor No. 2 malfunction (Including incorrect assembly)
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR DRIVER-SIDE SIDE AIR BAG SENSOR NO. 2
WIRING HARNESS-SIDE CONNECTOR
* * * * * * * *
3W 3T * * B A
3X 3U * * * *
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
SENSOR NO. 2 CONNECTOR No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-02–12
1871-1U-06B(08-02).fm 13 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT WIRING HARNESS BETWEEN Yes Replace the driver-side side air bag sensor No. 2, then go
DRIVER-SIDE SIDE AIR BAG SENSOR NO. 2 to the next step.
AND SAS CONTROL MODULE (See 08-10-14 SIDE AIR BAG SENSOR NO. 2
• Turn the ignition switch to the LOCK position. REMOVAL/INSTALLATION.)
• Disconnect the negative battery cable and No Replace the air bag wiring harness.
wait for 1 min or more.
• Disconnect the driver and passenger-side
front seat connectors.
• Remove the C-pillar trim.
(See 09-17-17 C-PILLAR TRIM REMOVAL/
INSTALLATION.)
• Remove the D-pillar trim.
(See 09-17-18 D-PILLAR TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors.
• Remove the console.
(See 09-17-13 CONSOLE REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connector.
• Disconnect the driver-side side air bag
sensor No. 2 connector.
• Connect the negative battery cable.
• Inspect the wiring harnesses between SAS
control module terminal 3X and driver-side
side air bag sensor No. 2 terminal A, SAS 08-02
control module terminal 3W and driver-side
side air bag sensor No. 2 terminal B for the
following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?
3 INSPECT SAS CONTROL MODULE Yes [Present malfunction diagnosis]
• Turn the ignition switch to the LOCK position. • Replace the SAS control module.
• Disconnect the negative battery cable and (See 08-10-10 SAS CONTROL MODULE REMOVAL/
wait for 1 min or more. INSTALLATION.)
• Connect the SAS control module connector. [Past malfunction diagnosis]
• Connect the driver-side side air bag sensor • DTC troubleshooting completed.
No. 2 connector.
• Are DTCs B1144, B1145 indicated? No DTC troubleshooting completed.
End Of Sie
08-02–13
1871-1U-06B(08-02).fm 14 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B1146, B1147
id080200809900
B1146 Passenger-side side air bag sensor No. 2 system internal circuit disabled
DTC
B1147 Passenger-side side air bag sensor No. 2 system communication error
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION
inspection procedure.
CONDITION
• Malfunction in wiring harness between passenger-side side air bag sensor No. 2 and SAS control
module
• Malfunction in passenger-side side air bag sensor No. 2 circuit
• Open or short circuit in wiring harness between passenger-side side air bag sensor No. 2 and SAS
POSSIBLE control module
CAUSE • Passenger-side side air bag sensor No. 2 malfunction (Including incorrect assembly)
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR PASSENGER-SIDE SIDE AIR BAG SENSOR NO. 2
WIRING HARNESS-SIDE CONNECTOR
* * * * * * * *
3W 3T * * B A
3X 3U * * * *
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PASSENGER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
SENSOR NO. 2 CONNECTOR No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-02–14
1871-1U-06B(08-02).fm 15 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT WIRING HARNESS BETWEEN Yes Replace the passenger-side side air bag sensor No. 2,
PASSENGER-SIDE SIDE AIR BAG SENSOR then go to the next step.
NO. 2 AND SAS CONTROL MODULE (See 08-10-14 SIDE AIR BAG SENSOR NO. 2
• Turn the ignition switch to the LOCK position. REMOVAL/INSTALLATION.)
• Disconnect the negative battery cable and No Replace the air bag wiring harness.
wait for 1 min or more.
• Disconnect the driver and passenger-side
front seat connectors.
• Remove the C-pillar trim.
(See 09-17-17 C-PILLAR TRIM REMOVAL/
INSTALLATION.)
• Remove the D-pillar trim.
(See 09-17-18 D-PILLAR TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connectors.
• Remove the console.
(See 09-17-13 CONSOLE REMOVAL/
INSTALLATION.)
• Disconnect the SAS control module
connector.
• Disconnect the passenger-side side air bag
sensor No. 2 connector.
• Connect the negative battery cable.
• Inspect the wiring harnesses between SAS
control module terminal 3U and passenger-
side side air bag sensor No. 2 terminal A, 08-02
SAS control module terminal 3T and
passenger-side side air bag sensor No. 2
terminal B for the following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?
3 INSPECT SAS CONTROL MODULE Yes [Present malfunction diagnosis]
• Turn the ignition switch to the LOCK position. • Replace the SAS control module.
• Disconnect the negative battery cable and (See 08-10-10 SAS CONTROL MODULE REMOVAL/
wait for 1 min or more. INSTALLATION.)
• Connect the SAS control module connector. [Past malfunction diagnosis]
• Connect the passenger-side side air bag • DTC troubleshooting completed.
sensor No. 2 connector.
• Are DTCs B1146, B1147 indicated. No DTC troubleshooting completed.
End Of Sie
DTC B1231
id080200801000
Diagnostic procedure
ACTION
Replace the SAS control module.
(See 08-10-10 SAS CONTROL MODULE REMOVAL/INSTALLATION.)
End Of Sie
08-02–15
1871-1U-06B(08-02).fm 16 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B1317, B1318
id080200811500
B1317 SAS control module power supply voltage increases (16.1 V or more)
DTC
B1318 SAS control module power supply voltage decreases (less than 8 V)
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION
an operating error, or damage the system. When performing an inspection, always follow the
CONDITION
inspection procedure.
• When the SAS control module power supply voltage is not within 816 V.
• Open or short circuit in wiring harness between battery and SAS control module
POSSIBLE • ARS 7.5 A fuse malfunction
CAUSE • Battery malfunction
• SAS control module malfunction
FUSE BLOCK
1V 1S 1P 1M 1J 1G 1D 1A AM AE W O I C
AN AF X P J D
1W 1T 1Q 1H 1E 1B
AO AG Y Q K E
1X 1U 1R 1I 1F 1C
AP AH Z R L F
AQ AI AA S G
AR AJ AB T
H
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT FUSE Yes Install the fuse, then go to the next step.
• Remove the ARS 7.5 A fuse. No Replace the fuse.
• Is the fuse normal?
2 INSPECT BATTERY Yes Go to the next step.
• Measure the battery positive voltage. No Battery is malfunctioning
• Is the voltage 8 V16 V? Inspect the charge/discharge system.
3 INSPECT WIRING HARNESS BETWEEN Yes Install the fuse, then go to the next step.
BATTERY AND FUSE BLOCK No Repair the wiring harness between the battery and fuse
• Turn the ignition switch to the ON position. block.
• Measure the fuse block terminal Y voltage.
• Is the voltage 8 V16 V?
08-02–16
1871-1U-06B(08-02).fm 17 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
4 INSPECT WIRING HARNESS BETWEEN FUSE Yes [Present malfunction diagnosis]
BLOCK AND SAS CONTROL MODULE • Replace the SAS control module.
(See 08-10-10 SAS CONTROL MODULE
Warning REMOVAL/INSTALLATION.)
• Handling the air bag system components [Past malfunction diagnosis]
improperly can accidentally deploy the air • DTC troubleshooting completed.
bag modules and pre-tensioner front No Replace the wiring harness between the fuse block and
buckles, which may seriously injure you. SAS control module.
Read the service warnings before handling
the air bag system components.
(See 08-10-3 AIR BAG SYSTEM SERVICE
WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM SERVICE
CAUTIONS.)
End Of Sie
DTC B1342
id080200801100
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Using the M-MDS, perform SAS control (See 08-10-10 SAS CONTROL MODULE REMOVAL/
module configuration. INSTALLATION.)
• Is DTC B1342 indicated? No DTC troubleshooting completed.
End Of Sie
08-02–17
1871-1U-06B(08-02).fm 18 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B1868
id080200815000
Diagnostic procedure
ACTION
INSPECT INSTRUMENT CLUSTER
Peform the “INSTRUMENT CLUSTER INPUT/OUTPUT CHECK MODE”.
(See 09-22-5 INSTRUMENT CLUSTER INPUT/OUTPUT CHECK MODE.)
End Of Sie
DTC B1877, B1878, B1879, B1885
id080200801400
B A
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE PRE-TENSIONER Yes Replace the SAS control module. (See 08-10-10 SAS
SEAT BELT CONTROL MODULE REMOVAL/INSTALLATION.)
• Using the M-MDS, verify the following PID/ No Go to the next step.
DATA monitor.
(See 08-02-8 PID/DATA MONITOR TABLE.)
— RES_PT_D
• Is driver-side pre-tensioner seat belt
resistance normal?
— Resistance: 1.53.7 ohms
08-02–18
1871-1U-06B(08-02).fm 19 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT DRIVER-SIDE PRE-TENSIONER Yes Replace the air bag wiring harness.
SEAT BELT CONNECTOR No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
End Of Sie
08-02–19
1871-1U-06B(08-02).fm 20 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B1881, B1882, B1883, B1886
id080200801500
B A
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE PRE-TENSIONER Yes Replace the SAS control module. (See 08-10-10 SAS
SEAT BELT CONTROL MODULE REMOVAL/INSTALLATION.)
• Using the M-MDS, verify the following PID/ No Go to the next step.
DATA monitor.
(See 08-02-8 PID/DATA MONITOR TABLE.)
— RES_PT_P
• Is passenger-side pre-tensioner resistance
normal?
— Resistance: 1.53.7 ohms
08-02–20
1871-1U-06B(08-02).fm 21 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT DRIVER-SIDE PRE-TENSIONER Yes Replace the air bag wiring harness.
SEAT BELT CONNECTOR No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
End Of Sie
08-02–21
1871-1U-06B(08-02).fm 22 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B1884, B1890
id080200801600
B1884 Passenger air bag deactivation (PAD) indicator circuit open or short to body ground
DTC
B1890 Passenger air bag deactivation (PAD) indicator circuit short to power supply
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION
an operating error, or damage the system. When performing an inspection, always follow the
CONDITION
inspection procedure.
1V 1S 1P 1M 1J 1G 1D 1A
* I * E C A
1W 1T 1Q 1H 1E 1B
L J H * D B
1X 1U 1R 1I 1F 1C
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT OPERATION OF PAD INDICATOR Yes Go to the next step.
• Turn the ignition switch to the ON position. No Go to Step 5.
• Does the PAD indicator illuminate?
2 INSPECT FUSE Yes Install the fuse, then go to the next step.
• Remove the MATER 10 A fuse. No Replace the fuse.
• Is the fuse normal?
3 INSPECT BATTERY Yes Go to the next step.
• Measure the battery positive voltage. No Battery is malfunctioning
• Is the voltage 9 V16 V? Inspect the charge/discharge system.
4 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
BATTERY AND PAD INDICATOR No Repair the wiring harness between the battery and
• Turn the ignition switch to the ON position. information display.
• Measure the information display connector
terminal E voltage.
• Is the voltage 9 V or more?
08-02–22
1871-1U-06B(08-02).fm 23 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
5 INSPECT WIRING HARNESS BETWEEN PAD Yes Go to the next step.
INDICATOR AND SAS CONTROL MODULE No Replace the air bag wiring harness.
Warning
• Handling the air bag system components
improperly can accidentally deploy the air
bag modules and pre-tensioner front
buckles, which may seriously injure you.
Read the service warnings before handling
the air bag system components.
(See 08-10-3 AIR BAG SYSTEM SERVICE
WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM SERVICE
CAUTIONS.)
End Of Sie
08-02–23
1871-1U-06B(08-02).fm 24 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B1913, B1916, B1932, B1934
id080200801700
Driver-side air bag module (inflator No.1) circuit short to body ground (air bag system warning light
B1913
DTC 19 is displayed.)
DTC B1916 Driver-side air bag module (inflator No.1) circuit short to power supply
B1932 Driver-side air bag module (inflator No.1) circuit resistance high
B1934 Driver-side air bag module (inflator No.1) circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION inspection procedure.
CONDITION
• Abnormal resistance (other than 1.4— 3.9 ohms) detected in the driver-side air bag module (inflator
No.1) circuit
• Malfunction in the wiring harness between the driver-side air bag module (inflator No.1) and SAS
control module
• Open or short circuit in the wiring harness between the clock spring and SAS control module
POSSIBLE • Clock spring malfunction
CAUSE • Driver-side air bag module (inflator No.1) malfunction
• SAS control module malfunction
1D 1C 1B 1A 3B 3A 4B 4A
1W 1T 1Q 1H 1E 1B
1X 1U 1R 1I 1F 1C
08-02–24
1871-1U-06B(08-02).fm 25 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE AIR BAG MODULE Yes Replace the SAS control module.
(INFLATOR NO.1) (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. (See 08-02-8 PID/DATA No Go to the next step.
MONITOR TABLE.)
— RES_AB_D
• Is the resistance of the driver-side air bag
module normal?
— Resistance: 1.4— 3.9 ohms
2 INSPECT DRIVER-SIDE AIR BAG MODULE Yes Replace the air bag wiring harness.
CONNECTOR (CLOCK SPRING) No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-02
• Turn the ignition switch to the LOCK position.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the driver-side air bag module.
(See 08-10-6 DRIVER-SIDE AIR BAG
MODULE REMOVAL/INSTALLATION.)
• Is there any malfunction of the driver-side air
bag module connector?
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
DRIVER-SIDE AIR BAG MODULE (INFLATOR No Replace the driver-side air bag module.
NO.1) OR RELATED WIRING HARNESS (See 08-10-6 DRIVER-SIDE AIR BAG MODULE
• Connect the leads of the SST (Fuel and REMOVAL/INSTALLATION.)
thermometer checker) or apply 2-ohm
resistance to driver-side air bag module
(inflator No.1) connector terminals 3A and
3B, and driver-side air bag module (inflator
No.2) connector terminals 4A and 4B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm
position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1913, B1916, B1932 and/or
B1934 indicated?
4 INSPECT CLOCK SPRING Yes Go to the next step.
• Inspect the clock spring. No Replace the clock spring.
(See 08-10-16 CLOCK SPRING (See 08-10-15 CLOCK SPRING REMOVAL/
INSPECTION.) INSTALLATION.)
• Is the clock spring normal?
08-02–25
1871-1U-06B(08-02).fm 26 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
5 INSPECT WIRING HARNESS BETWEEN Yes Replace the SAS control module.
CLOCK SPRING AND SAS CONTROL (See 08-10-10 SAS CONTROL MODULE REMOVAL/
MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector.
• Remove the glove compartment.(See 09-17-
8 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector.
• Disconnect the driver and passenger-side
seat connectors.
• Remove the C-pillar trim. (See 09-17-17 C-
PILLAR TRIM REMOVAL/INSTALLATION.)
• Remove the D-pillar trim. (See 09-17-18 D-
PILLAR TRIM REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connector.
• Remove the B-pillar lower trim. (See 09-17-
16 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors.
• Remove the console. (See 09-17-13
CONSOLE REMOVAL/INSTALLATION.)
• Disconnect the SAS control module
connector.
• Inspect the wiring harness between SAS
control module terminal 1S and clock spring
terminal 1D, SAS control module terminal 1V
and clock spring terminal 1C for the
following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?
End Of Sie
08-02–26
1871-1U-06B(08-02).fm 27 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B1913, B1925, B1933, B1935
id080200801800
Passenger-side air bag module (inflator No.1) circuit short to body ground (air bag system warning
B1913
light DTC 21 is displayed.)
DTC B1925 Passenger-side air bag module (inflator No.1) circuit short to power supply
B1933 Passenger-side air bag module (inflator No.1) circuit resistance high
B1935 Passenger-side air bag module (inflator No.1) circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION inspection procedure.
CONDITION
• Abnormal resistance (other than 1.4— 3.6 ohms) detected in the passenger-side air bag module
(inflator No.1) circuit
• Malfunction in the wiring harness between the passenger-side air bag module (inflator No.1) and SAS
control module
• Open or short circuit in the wiring harness between the passenger-side air bag module (inflator No.1)
POSSIBLE and SAS control module
CAUSE • Passenger-side air bag module (inflator No.1) malfunction
• SAS control module malfunction
B A B A 08-02
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PASSENGER-SIDE AIR BAG Yes Replace the SAS control module.
MODULE (INFLATOR NO.1) (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-8 PID/DATA MONITOR TABLE.)
— RES_AB_P
• Is the resistance of the passenger-side air
bag module normal?
— Resistance: 1.4— 3.6 ohms
08-02–27
1871-1U-06B(08-02).fm 28 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT PASSENGER-SIDE AIR BAG Yes Replace the air bag wiring harness.
MODULE (INFLATOR NO.1) CONNECTOR No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
End Of Sie
08-02–28
1871-1U-06B(08-02).fm 29 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B1992, B1993, B1994, B1995
id080200801900
B1992 Driver-side side air bag module circuit short to power supply
B1993 Driver-side side air bag module circuit short to body ground
DTC
B1994 Driver-side side air bag module circuit resistance high
B1995 Driver-side side air bag module circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.
• Abnormal resistance (other than 1.4— 3.9 ohms) detected in the driver-side side air bag module circuit
• Malfunction in the wiring harness between the driver-side side air bag module and SAS control module
• Open or short circuit in the wiring harness between the driver-side side air bag module and SAS control
POSSIBLE module
CAUSE • Driver-side side air bag module malfunction
• SAS control module malfunction
B A
08-02
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE SIDE AIR BAG Yes Replace the SAS control module.
MODULE (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-8 PID/DATA MONITOR TABLE.)
— RES_SAB_D
• Is the resistance of the driver-side side air
bag module normal?
— Resistance: 1.4— 3.9 ohms
2 INSPECT DRIVER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
MODULE CONNECTOR No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-02–29
1871-1U-06B(08-02).fm 30 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
3 VERIFY WHETHER MALFUNCTION IS IN Yes Replace the air bag wiring harness, then go to the next
DRIVER-SIDE SIDE AIR BAG MODULE OR step.
RELATED WIRING HARNESS No Replace the driver-side side air bag module.
• Connect the leads of the SST (Fuel and (See 08-10-8 SIDE AIR BAG MODULE REMOVAL/
thermometer checker) or apply 2-ohm INSTALLATION.)
resistance to driver-side side air bag module
connector terminals A and B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm
position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1992, B1993, B1994, and/or
B1995 indicated?
4 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Turn the ignition switch to the LOCK position. (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Disconnect the negative battery cable and INSTALLATION.)
wait for 1 min or more. No DTC troubleshooting completed.
• Connect the driver-side side air bag module
connector.
• Turn the ignition switch to the ON position.
• Are DTCs B1992, B1993, B1994, and/or
B1995 indicated?
End Of Sie
DTC B1996, B1997, B1998, B1999
id080200802000
B1996 Passenger-side side air bag module circuit short to power supply
B1997 Passenger-side side air bag module circuit short to body ground
DTC
B1998 Passenger-side side air bag module circuit resistance high
B1999 Passenger-side side air bag module circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION inspection procedure.
CONDITION
• Abnormal resistance (other than 1.4— 3.9 ohms) detected in the passenger-side side air bag module
circuit
• Malfunction in the wiring harness between the passenger-side side air bag module and SAS control
module
• Open or short circuit in the wiring harness between the passenger-side side air bag module and SAS
POSSIBLE control module
CAUSE • Passenger-side side air bag module malfunction
• SAS control module malfunction
B A
08-02–30
1871-1U-06B(08-02).fm 31 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT passenger-side side AIR BAG Yes Replace the SAS control module.
MODULE (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-8 PID/DATA MONITOR TABLE.)
— RES_SAB_P
• Is the resistance of the passenger-side side
air bag module normal?
— Resistance: 1.4— 3.9 ohms
2 INSPECT DRIVER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
MODULE CONNECTOR No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-02
• Turn the ignition switch to the LOCK position.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Disconnect the passenger-side side air bag
module connector.
• Is there any malfunction of the passenger-
side side air bag module connector?
3 VERIFY WHETHER MALFUNCTION IS IN Yes Replace the air bag wiring harness, then go to the next
DRIVER-SIDE SIDE AIR BAG MODULE OR step.
RELATED WIRING HARNESS No Replace the passenger-side side air bag module.
• Connect the leads of the SST (Fuel and (See 08-10-8 SIDE AIR BAG MODULE REMOVAL/
thermometer checker) or apply 2-ohm INSTALLATION.)
resistance to passenger-side side air bag
module connector terminals A and B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm
position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B1996, B1997, B1998, and/or
B1999 indicated?
4 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Turn the ignition switch to the LOCK position. (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Disconnect the negative battery cable and INSTALLATION.)
wait for 1 min or more. No DTC troubleshooting completed.
• Connect the passenger-side side air bag
module connector.
• Turn the ignition switch to the ON position.
• Are DTCs B1996, B1997, B1998, and/or
B1999 indicated?
End Of Sie
08-02–31
1871-1U-06B(08-02).fm 32 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B2228, B2230, B2232, B2234
id080200802100
B2228 Driver-side air bag module (inflator No.2) circuit short to body ground
B2230 Driver-side air bag module (inflator No.2) circuit short to power supply
DTC
B2232 Driver-side air bag module (inflator No.2) circuit resistance high
B2234 Driver-side air bag module (inflator No.2) circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION inspection procedure.
CONDITION
• Abnormal resistance (other than 1.5— 4.4 ohms) detected in the driver-side air bag module (inflator
No.2) circuit
• Malfunction in the wiring harness between the driver-side air bag module (inflator No.2) and SAS
control module
• Open or short circuit in the wiring harness between the clock spring and SAS control module
POSSIBLE • Clock spring malfunction
CAUSE • Driver-side air bag module (inflator No.2) malfunction
• SAS control module malfunction
1D 1C 1B 1A 3B 3A 4B 4A
1W 1T 1Q 1H 1E 1B
1X 1U 1R 1I 1F 1C
08-02–32
1871-1U-06B(08-02).fm 33 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE AIR BAG MODULE Yes Replace the SAS control module.
(INFLATOR NO.1) (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. (See 08-02-8 PID/DATA No Go to the next step.
MONITOR TABLE.)
— RES_AB2_D
• Is the resistance of the driver-side air bag
module normal?
— Resistance: 1.5— 4.4 ohms
2 INSPECT DRIVER-SIDE AIR BAG MODULE Yes Replace the air bag wiring harness.
CONNECTOR (CLOCK SPRING) No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-02
• Turn the ignition switch to the LOCK position.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the driver-side air bag module.
(See 08-10-6 DRIVER-SIDE AIR BAG
MODULE REMOVAL/INSTALLATION.)
• Is there any malfunction of the driver-side air
bag module connector?
3 VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.
DRIVER-SIDE AIR BAG MODULE (INFLATOR No Replace the driver-side air bag module.
NO.1) OR RELATED WIRING HARNESS (See 08-10-6 DRIVER-SIDE AIR BAG MODULE
• Connect the leads of the SST (Fuel and REMOVAL/INSTALLATION.)
thermometer checker) or apply 2-ohm
resistance to driver-side air bag module
(inflator No.1) connector terminals 3A and
3B, and driver-side air bag module (inflator
No.2) connector terminals 4A and 4B.
• Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm
position.
• Connect the negative battery cable.
• Turn the ignition switch to the ON position.
• Are DTCs B2228, B2230, B2232 and/or
B2234 indicated?
4 INSPECT CLOCK SPRING Yes Go to the next step.
• Inspect the clock spring. No Replace the clock spring.
(See 08-10-16 CLOCK SPRING (See 08-10-15 CLOCK SPRING REMOVAL/
INSPECTION.) INSTALLATION.)
• Is the clock spring normal?
08-02–33
1871-1U-06B(08-02).fm 34 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
5 INSPECT WIRING HARNESS BETWEEN Yes Replace the SAS control module.
CLOCK SPRING AND SAS CONTROL (See 08-10-10 SAS CONTROL MODULE REMOVAL/
MODULE INSTALLATION.)
• Turn the ignition switch to the LOCK position. No Replace the air bag wiring harness.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector.
• Remove the glove compartment.(See 09-17-
8 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector.
• Disconnect the driver and passenger-side
seat connectors.
• Remove the C-pillar trim. (See 09-17-17 C-
PILLAR TRIM REMOVAL/INSTALLATION.)
• Remove the D-pillar trim. (See 09-17-18 D-
PILLAR TRIM REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connector.
• Remove the B-pillar lower trim. (See 09-17-
16 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors.
• Remove the console. (See 09-17-13
CONSOLE REMOVAL/INSTALLATION.)
• Disconnect the SAS control module
connector.
• Inspect the wiring harness between SAS
control module terminal 1G and clock spring
terminal 1B, SAS control module terminal 1J
and clock spring terminal 1A for the
following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?
End Of Sie
08-02–34
1871-1U-06B(08-02).fm 35 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B2229, B2231, B2233, B2235
id080200802200
B2229 Passenger-side air bag module (inflator No.2) circuit short to body ground
B2231 Passenger-side air bag module (inflator No.2) circuit short to power supply
DTC
B2233 Passenger-side air bag module (inflator No.2) circuit resistance high
B2235 Passenger-side air bag module (inflator No.2) circuit resistance low
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION inspection procedure.
CONDITION
• Abnormal resistance (other than 1.4— 3.9 ohms) detected in the passenger-side air bag module
(inflator No.2) circuit
• Malfunction in the wiring harness between the passenger-side air bag module (inflator No.2) and SAS
control module
• Open or short circuit in the wiring harness between the passenger-side air bag module (inflator No.2)
POSSIBLE and SAS control module
CAUSE • Passenger-side air bag module (inflator No.2) malfunction
• SAS control module malfunction
B A B A
08-02
08-02–35
1871-1U-06B(08-02).fm 36 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PASSENGER-SIDE AIR BAG Yes Replace the SAS control module.
MODULE (INFLATOR NO.1) (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-8 PID/DATA MONITOR TABLE.)
— RES_AB2_P
• Is the resistance of the passenger-side air
bag module normal?
— Resistance: 1.4— 3.9 ohms
2 INSPECT PASSENGER-SIDE AIR BAG Yes Replace the air bag wiring harness.
MODULE (INFLATOR NO.1) CONNECTOR No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
End Of Sie
08-02–36
1871-1U-06B(08-02).fm 37 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B2290
id080200802300
1V 1S 1P 1M 1J 1G 1D 1A
* * 3A
* 3D 3B
1W 1T 1Q 1H 1E 1B
1X 1U 1R 1I 1F 1C
08-02
08-02–37
1871-1U-06B(08-02).fm 38 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
3 INSPECT PASSENGER SENSING SYSTEM Yes Go to the next step.
• Connect the seat weight sensor control No Replace the following parts according to the M-MDS
module connector. screen:
• Connect the SAS control module. • If OCSFLT_CAL is displayed:
• Connect the negative battery cable. — Perform seat weight sensor calibration (See 08-10-
• Verify the following PIDs using the M-MDS. 12 SEAT WEIGHT SENSOR CALIBRATION.)
(See 08-02-8 PID/DATA MONITOR TABLE.) • If OCSFLT_COM or OCSFLT_MDL is displayed:
— OCSFLT_CAL — Seat weight sensor control module (See 08-10-11
— OCSFLT_COM SEAT WEIGHT SENSOR CONTROL MODULE
— OCSFLT_L REMOVAL/INSTALLATION.)
— OCSFLT_MDL • If OCSFLT_L is displayed:
— OCSFLT_R — Seat weight sensor (LH) (See: 09-13-2 FRONT
• Do all PIDs display “OK”? SEAT DISASSEMBLY/ASSEMBLY.)
• If OCSFLT_R is displayed:
— Seat weight sensor (RH) (See 09-13-2 FRONT
SEAT DISASSEMBLY/ASSEMBLY.)
4 INSPECT SAS CONTROL MODULE Yes [Present malfunction diangnosis]
• Reperform the DTC inspection. • Replace the SAS control module.
• Is DTC B2290 indicated? (See 08-10-10 SAS CONTROL MODULE REMOVAL/
INSTALLATION.)
[Past malfunction diagnosis]
• DTC troubleshooting completed.
No DTC troubleshooting completed.
End Of Sie
DTC B2296
id080200802400
DTC B2296 Crash zone sensor (communication error, internal circuit abnormal)
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
DETECTION an operating error, or damage the system. When performing an inspection, always follow the
CONDITION inspection procedure.
• Malfunction in the wiring harness between the crash zone sensor and SAS control module
• Malfunction in the crash zone sensor circuit
• Open or short circuit in the wiring harness between the crash zone sensor and SAS control module
POSSIBLE
• SAS control module malfunction
CAUSE
• Crash zone sensor malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR CRASH ZONE SENSOR WIRING
HARNESS-SIDE CONNECTOR
1V 1S 1P 1M 1J 1G 1D 1A
1W 1T 1Q 1H 1E 1B B A
1X 1U 1R 1I 1F 1C
08-02–38
1871-1U-06B(08-02).fm 39 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT CRASH ZONE SENSOR Yes Replace the air bag wiring harness.
No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-02–39
1871-1U-06B(08-02).fm 40 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
3 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Turn the ignition switch to the LOCK position. (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Disconnect the negative battery cable and INSTALLATION.)
wait for 1 min or more. No DTC troubleshooting completed.
• Connect the SAS control module connector.
• Connect the crash zone sensor connector.
• Turn the ignition switch to the ON position.
• Is DTC B2296 indicated?
End Of Sie
DTC B2444, U2017
id080200802700
B2444 Driver-side side air bag sensor No.1 (internal circuit abnormal)
DTC
U2017 Driver-side side air bag sensor No.1 (communication error)
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION
inspection procedure.
CONDITION
• Malfunction in the wiring harness between the driver-side side air bag sensor No.1 and SAS control
module
• Malfunction in the driver-side side air bag sensor circuit
• Open or short circuit in the wiring harness between the driver-side side air bag sensor No.1 and SAS
POSSIBLE control module
CAUSE • Driver-side side air bag sensor malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING
DRIVER-SIDE SIDE AIR BAG SENSOR NO.1
HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
2Y 2V 2S 2P 2M 2J 2G 2D 2A
B A
2Z 2W 2T 2H 2E 2B
2AA 2X 2U 2R 2O 2L 2I 2F 2C
08-02–40
1871-1U-06B(08-02).fm 41 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
SENSOR NO. 1 CONNECTOR No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-02–41
1871-1U-06B(08-02).fm 42 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
DRIVER-SIDE SIDE AIR BAG SENSOR NO.1 No Replace the air bag wiring harness.
AND SAS CONTROL MODULE
• Turn the ignition switch to the LOCK position.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector.
• Remove the glove compartment.(See 09-17-
8 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector.
• Disconnect the driver and passenger-side
seat connectors.
• Disconnect the driver and passenger-side
curtain air bag module connector.
• Remove the B-pillar lower trim. (See 09-17-
16 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors.
• Disconnect the driver-side side air bag
sensor No.1 connector.
• Remove the console. (See 09-17-13
CONSOLE REMOVAL/INSTALLATION.)
• Disconnect the SAS control module
connector.
• Connect the negative battery cable.
• Inspect the wiring harnesses between SAS
control module connector terminal 2AA and
driver-side side air bag sensor No.1
connector terminal A, SAS control module
connector terminal 2Z and driver-side side
air bag sensor No.1 connector terminal B for
the following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?
3 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Turn the ignition switch to the LOCK position. (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Disconnect the negative battery cable and INSTALLATION.)
wait for 1 min or more. No DTC troubleshooting completed.
• Connect the SAS control module connector.
• Connect the driver-side side air bag sensor
No.1 connector.
• Turn the ignition switch to the ON position.
• Are DTCs B2444 and/or U2017 indicated?
End Of Sie
08-02–42
1871-1U-06B(08-02).fm 43 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B2445, U2018
id080200802800
B2445 Passenger-side side air bag sensor No.1 (internal circuit abnormal)
DTC
U2018 Passenger-side side air bag sensor No.1 (communication error)
Warning
• Detection conditions are for understanding the DTC outline before performing an inspection.
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION
inspection procedure.
CONDITION
• Malfunction in the wiring harness between the passenger-side side air bag sensor and SAS control
module
• Malfunction in the passenger-side side air bag sensor circuit
• Open or short circuit in the wiring harness between the passenger-side side air bag sensor and SAS
POSSIBLE control module
CAUSE • Passenger-side side air bag sensor malfunction
• SAS control module malfunction
SAS CONTROL MODULE WIRING
PASSENGER-SIDE SIDE AIR BAG SENSOR NO.1
HARNESS-SIDE CONNECTOR
WIRING HARNESS-SIDE CONNECTOR
2Y 2V 2S 2P 2M 2J 2G 2D 2A
B A
2Z 2W 2T 2H 2E 2B
2AA 2X 2U 2R 2O 2L 2I 2F 2C
08-02
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PASSENGER-SIDE SIDE AIR BAG Yes Replace the air bag wiring harness.
SENSOR NO. 1 CONNECTOR No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-02–43
1871-1U-06B(08-02).fm 44 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
PASSENGER-SIDE SIDE AIR BAG SENSOR No Replace the air bag wiring harness.
NO.1 AND SAS CONTROL MODULE
• Turn the ignition switch to the LOCK position.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector.
• Remove the glove compartment. (See 09-17-
8 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector.
• Disconnect the driver and passenger-side
seat connectors.
• Remove the C-pillar trim. (See 09-17-17 C-
PILLAR TRIM REMOVAL/INSTALLATION.)
• Remove the D-pillar trim. (See 09-17-18 D-
PILLAR TRIM REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connector.
• Remove the B-pillar lower trim. (See 09-17-
16 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors.
• Disconnect the passenger-side side air bag
sensor No.1 connector.
• Remove the console. (See 09-17-13
CONSOLE REMOVAL/INSTALLATION.)
• Disconnect the SAS control module
connector.
• Connect the negative battery cable.
• Inspect the wiring harnesses between SAS
control module connector terminal 2C and
passenger-side side air bag sensor No.1
connector terminal A, SAS control module
connector terminal 2B and passenger-side
side air bag sensor No.1 connector terminal
B for the following:
— Short to ground
— Short to power supply
— Open circuit
• Is the wiring harness normal?
3 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Turn the ignition switch to the LOCK position. (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Disconnect the negative battery cable and INSTALLATION.)
wait for 1 min or more. No DTC troubleshooting completed.
• Connect the SAS control module connector.
• Connect the passenger-side side air bag
sensor No.1 connector.
• Turn the ignition switch to the ON position.
• Are DTCs B2445 and/or U2018 indicated?
End Of Sie
08-02–44
1871-1U-06B(08-02).fm 45 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B2477
id080200810500
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module.
• Using the M-MDS, perform SAS control (See 08-10-10 SAS CONTROL MODULE REMOVAL/
moduleconfiguration. INSTALLATION.)
• Is DTC B2477 indicated? No DTC troubleshooting completed.
End Of Sie
DTC B2773, B2774, B2775, B2776
id080200802900
B A
08-02–45
1871-1U-06B(08-02).fm 46 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT DRIVER-SIDE CURTAIN AIR BAG Yes Replace the SAS control module.
MODULE (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-8 PID/DATA MONITOR TABLE.)
— RES_CAB_D
• Is the resistance of the driver-side curtain air
bag module normal?
— Resistance: 1.4— 3.9 ohms
2 INSPECT DRIVER-SIDE CURTAIN AIR BAG Yes Replace the air bag wiring harness.
MODULE CONNECTOR No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
End Of Sie
08-02–46
1871-1U-06B(08-02).fm 47 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B2777, B2778, B2779, B2780
id080200803000
B A
08-02
08-02–47
1871-1U-06B(08-02).fm 48 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT PASSENGER-SIDE CURTAIN AIR Yes Replace the SAS control module.
BAG MODULE (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Using the M-MDS, verify the following PID/ INSTALLATION.)
DATA monitor. No Go to the next step.
(See 08-02-8 PID/DATA MONITOR TABLE.)
— RES_CAB_P
• Is the resistance of the passenger-side
curtain air bag module normal?
— Resistance: 1.4— 3.9 ohms
2 INSPECT DRIVER-SIDE CURTAIN AIR BAG Yes Replace the air bag wiring harness.
MODULE CONNECTOR No Go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
End Of Sie
08-02–48
1871-1U-06B(08-02).fm 49 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
DTC B2867
id080200803100
• There is no continuity between the poor connection detector bar terminals of the SAS control module.
• Poor connection of any SAS control module connectors
POSSIBLE
• Malfunction of any SAS control module connectors
CAUSE
• SAS control module malfunction
SAS CONTROL MODULE WIRING
HARNESS-SIDE CONNECTOR
1V 1S 1P 1M 1J 1G 1D 1A 2Y 2V 2S 2P 2M 2J 2G 2D 2A * * * * * * * *
1W 1T 1Q 1H 1E 1B 2Z 2W 2T 2H 2E 2B 3W 3T * *
1X 1U 1R 1I 1F 1C 2AA 2X 2U 2R 2O 2L 2I 2F 2C 3X 3U * * * *
08-02
Diagnostic procedure
STEP INSPECTION ACTION
1 VERIFY THAT ALL SAS CONTROL MODULE Yes Go to the next step.
CONNECTORS ARE CONNECTED WITH SAS No Reconnect the connector properly.
CONTROL MODULE
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-02–49
1871-1U-06B(08-02).fm 50 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
2 INSPECT ALL SAS CONTROL MODULE Yes Replace the SAS control module.
CONNECTORS (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Remove the column cover. (See 09-17-8 INSTALLATION.)
COLUMN COVER REMOVAL/ No Replace the air bag wiring harness.
INSTALLATION.)
• Disconnect the clock spring connector.
• Remove the glove compartment.(See 09-17-
8 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector.
• Disconnect the driver and passenger-side
seat connectors.
• Remove the C-pillar trim. (See 09-17-17 C-
PILLAR TRIM REMOVAL/INSTALLATION.)
• Remove the D-pillar trim. (See 09-17-18 D-
PILLAR TRIM REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connector.
• Remove the B-pillar lower trim. (See 09-17-
16 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors.
• Remove the console. (See 09-17-13
CONSOLE REMOVAL/INSTALLATION.)
• Disconnect the SAS control module
connector.
• Are the poor connection detector bars of
SAS control module connectors normal?
End Of Sie
DTC C1947, C1948, C1981
id080200803200
2Y 2V 2S 2P 2M 2J 2G 2D 2A A C
* *
2Z 2W 2T 2H 2E 2B
2AA 2X 2U 2R 2O 2L 2I 2F 2C
08-02–50
1871-1U-06B(08-02).fm 51 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1 INSPECT SEAT TRACK POSITION SENSOR Yes [Present malfunction diagnosis]
CIRCUIT • Replace the SAS control module.
• Using the M-MDS, verify the following PID/ (See 08-10-10 SAS CONTROL MODULE REMOVAL/
DATA monitor. INSTALLATION.)
(See 08-02-8 PID/DATA MONITOR TABLE.) [Past malfunction diagnosis]
— TRAK_SW • DTC troubleshooting completed.
• Is the seat track position sensor circuit
No Go to the next step.
normal?
2 INSPECT WIRING HARNESS BETWEEN Yes Replace the seat track position sensor, then go to the next
SEAT TRACK POSITION SENSOR AND SAS step.
CONTROL MODULE No Replace wiring harness, then go to the next step.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-02
• Turn the ignition switch to the LOCK position.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector.
• Remove the glove compartment.(See 09-17-
8 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector.
• Disconnect the driver and passenger-side
seat connectors.
• Remove the C-pillar trim. (See 09-17-17 C-
PILLAR TRIM REMOVAL/INSTALLATION.)
• Remove the D-pillar trim. (See 09-17-18 D-
PILLAR TRIM REMOVAL/INSTALLATION.)
• Disconnect the driver and passenger-side
curtain air bag module connector.
• Remove the B-pillar lower trim. (See 09-17-
16 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors.
• Remove the console. (See 09-17-13
CONSOLE REMOVAL/INSTALLATION.)
• Disconnect the SAS control module
connector.
• Disconnect the seat track position sensor
connector
• Inspect the wiring harness between SAS
control module terminal and seat track
position sensor terminals for short to ground,
short to power supply, and open circuit:
— 2W— C
— 2X— A
• Is the wiring harness normal?
08-02–51
1871-1U-06B(08-02).fm 52 ページ 2006年3月15日 水曜日 午前11時33分
ON-BOARD DIAGNOSTIC
STEP INSPECTION ACTION
3 INSPECT SAS CONTROL MODULE Yes [Present malfunction diagnosis]
• Turn the ignition switch to the LOCK position. • Replace the SAS control module.
• Connect the SAS control module connector. (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Connect the clock spring connector. INSTALLATION.)
• Connect the passenger-side air bag module [Past malfunction diagnosis]
connector. • DTC troubleshooting completed.
• Connect the driver-and passenger-side
curtain air bag module connectors. No DTC troubleshooting completed.
• Connect the driver-and passenger-side side
air bag module connectors.
• Connect the driver-and passenger-side pre
tensioner seat belt connectors.
• Connect the seat track position sensor
connector.
• Turn the ignition switch to the ON position.
• Are DTCs C1947, C1948 and/or C1981
indicated?
End Of Sie
08-02–52
1871-1U-06B(08-03).fm 1 ページ 2006年3月15日 水曜日 午前11時35分
SYMPTOM TROUBLESHOOTING
08-03 SYMPTOM TROUBLESHOOTING
TROUBLESHOOTING INDEX. . . . . . . . . 08-03–1 NO.2 AIR BAG SYSTEM WARNING
NO.1 AIR BAG SYSTEM WARNING LIGHT ILLUMINATES
LIGHT DOES NOT ILLUMINATE . . . . . 08-03–1 CONSTANTLY . . . . . . . . . . . . . . . . . . . . 08-03–3
Diagnostic Procedure. . . . . . . . . . . . . . 08-03–1 Diagnostic Procedure . . . . . . . . . . . . . . 08-03–3
End of Toc
TROUBLESHOOTING INDEX
WM: AIR BAG SYSTEM
id080300802000
• Use the chart below verify the symptoms of the trouble in order to diagnose the appropriate area.
No. Troubleshooting item Description Page
1 Air bag system warning light does not Malfunction in air bag system warning (See 08-03-1 NO.1 AIR BAG SYSTEM
illuminate. light circuit (short to ground). WARNING LIGHT DOES NOT
ILLUMINATE)
2 Air bag system warning light is Malfunction in air bag system warning (See 08-03-3 NO.2 AIR BAG SYSTEM
illuminated constantly. light circuit (open circuit or short to WARNING LIGHT ILLUMINATES
power supply). CONSTANTLY)
End Of Sie
NO.1 AIR BAG SYSTEM WARNING LIGHT DOES NOT ILLUMINATE
id080300800200
Diagnostic Procedure
STEP INSPECTION ACTION
1 INSPECT OTHER WARNING AND INDICATOR Yes Turn the ignition switch to the LOCK position, then go to the
LIGHTS CIRCUIT IN INSTRUMENT CLUSTER next step.
• Turn the ignition switch to the ON position. No Inspect the instrument cluster power supply system and
• Do other warning and indicator lights ground system, then go to Step 4.
illuminate?
2 INSPECT DTCS IN SAS CONTROL MODULE Yes Perform the applicable DTC inspection, then go to Step 5.
• Inspect the DTC for the SAS control module (See 08-02-4 DTC TABLE.)
on-board diagnostic system. No Go to the next step.
• Have DTCs been recorded in memory?
08-03–1
1871-1U-06B(08-03).fm 2 ページ 2006年3月15日 水曜日 午前11時35分
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
3 INSPECT SAS CONTROL MODULE Yes Replace the SAS control module, then go to Step 5.
(See 08-10-10 SAS CONTROL MODULE REMOVAL/
Warning INSTALLATION.)
• Handling the air bag system No Go to the next step.
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the air baga system service warnings
and cautions before handling the air
bag system components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-03–2
1871-1U-06B(08-03).fm 3 ページ 2006年3月15日 水曜日 午前11時35分
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
5 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Complete troubleshooting, then explain repairs to customer.
DO NOT RECUR AFTER REPAIR No Recheck malfunction symptoms, then repeat from Step 1 if
• Turn the ignition switch to LOCK position. malfunction recurs.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Connect all SAS control module connectors.
• Connect the driver and passenger-side
pre-tensioner seat belt connectors.
• Connect the driver and passenger-side
curtain air bag module connectors.
• Connect the driver and passenger-side front
seat connectors.
• Connect the passenger-side air bag module
connector.
• Connect the clock spring connector.
• Connect the negative battery cable.
• Turn the ignition switch to ON position.
• Does the air bag system warning light
operate properly?
End Of Sie
NO.2 AIR BAG SYSTEM WARNING LIGHT ILLUMINATES CONSTANTLY
id080300800300
Diagnostic Procedure
STEP INSPECTION ACTION
1 INSPECT BATTERY Yes Go to the next step.
• Measure the voltage of battery. No Battery is weak.
• Is the voltage 9 V or more? Inspect charge/discharge system, then go to Step 10.
(See 01-17-2 BATTERY INSPECTION[L3 WITH TC].)
08-03–3
1871-1U-06B(08-03).fm 4 ページ 2006年3月15日 水曜日 午前11時35分
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
2 VERIFY THAT SAS CONTROL MODULE Yes Go to the next step.
CONNECTOR IS CONNECTED No Reconnect the connector properly, then go to Step 10.
Warning
• Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the air bag system service warnings
and cautions before handling the air
bag system components.
(See 08-10-3 AIR BAG SYSTEM
SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM
SERVICE CAUTIONS.)
08-03–4
1871-1U-06B(08-03).fm 5 ページ 2006年3月15日 水曜日 午前11時35分
SYMPTOM TROUBLESHOOTING
STEP INSPECTION ACTION
8 INSPECT WIRING HARNESS BETWEEN Yes Go to the next step.
BATTERY AND FUSE BLOCK No Repair the wiring harnesses, then go to Step 10.
• Connect the negative battery cable.
• Turn the ignition switch to ON position.
• Measure the voltage at instrument cluster
connector terminal 2G.
• Is the voltage 8 V— 16 V?
9 VERIFY THAT SAS CONTROL MODULE Yes Replace the SAS control module, then go to the next step.
CONNECTOR TERMINAL 1X IS GROUND (See 08-10-10 SAS CONTROL MODULE REMOVAL/
• Turn the ignition switch to LOCK position. INSTALLATION.)
• Disconnect the negative battery cable and No Replace the wiring harnesses, then go to the next step.
wait for 1 min or more.
• Remove the column cover. (See 09-17-8
COLUMN COVER REMOVAL/
INSTALLATION.)
• Disconnect the clock spring connector.
• Remove the glove compartment. (See 09-17-
8 GLOVE COMPARTMENT REMOVAL/
INSTALLATION.)
• Disconnect the passenger-side air bag
module connector.
• Disconnect the driver and passenger-side
side air bag module connectors.
• Remove the C-pillar trims. (See 09-17-17 C-
PILLAR TRIM REMOVAL/INSTALLATION.)
• Remove the D-pillar trims. (See 09-17-18 D-
PILLAR TRIM REMOVAL/INSTALLATION.) 08-03
• Disconnect the driver and passenger-side
curtain air bag module connectors.
• Remove the B-pillar lower trims. (See 09-17-
16 B-PILLAR LOWER TRIM REMOVAL/
INSTALLATION.)
• Disconnect the driver and passenger-side
pre-tensioner seat belt connectors.
• Remove the console. (See 09-17-13
CONSOLE REMOVAL/INSTALLATION.)
• Disconnect all SAS control module control
model connectors.
• Inspect the wiring harness between SAS
control module connector terminal 1X and
ground for the following:
— Short to power supply
— Open circuit
• Is the wiring harness normal?
10 CONFIRM THAT MALFUNCTION SYMPTOMS Yes Complete troubleshooting, then explain repairs to customer.
DO NOT RECUR AFTER REPAIR No Recheck malfunction symptoms, then repeat from Step 1 if
• Turn the ignition switch to LOCK position. malfunction recurs.
• Disconnect the negative battery cable and
wait for 1 min or more.
• Connect all SAS control module connectors.
• Connect the driver and passenger-side
pre-tensioner seat belt connectors.
• Connect the driver and passenger-side
curtain air bag module connectors.
• Connect the driver and passenger-side front
seat connectors.
• Connect the passenger-side air bag module
connector.
• Connect the clock spring connector.
• Connect the instrument cluster connector.
• Connect the negative battery cable.
• Turn the ignition switch to ON position.
• Does the air bag system warning light
operate properly?
End Of Sie
08-03–5
1871-1U-06B(08-10).fm 1 ページ 2006年3月15日 水曜日 午前11時36分
End of Toc
WM: AIR BAG SYSTEM
08-10–1
1871-1U-06B(08-10).fm 2 ページ 2006年3月15日 水曜日 午前11時36分
3
1
2
4
9 10
7
5
12
8 11
acxuuw00001173
.
08-10–2
1871-1U-06B(08-10).fm 3 ページ 2006年3月15日 水曜日 午前11時36分
End Of Sie
AIR BAG SYSTEM SERVICE WARNINGS
id081000800200
Air Bag Module Inspection
• Inspecting an air bag module using a tester
NO GOOD
can operate (deploy) the air bag module,
which may cause serious injury. Do not use a
tester to inspect an air bag module. Always
use the on-board diagnostic function to
diagnose the air bag module for malfunctions.
acxuuw00001174
GOOD NO GOOD
acxuuw00001175
acxuuw00001176
08-10–3
1871-1U-06B(08-10).fm 4 ページ 2006年3月15日 水曜日 午前11時36分
08-10–4
1871-1U-06B(08-10).fm 5 ページ 2006年3月15日 水曜日 午前11時36分
NO GOOD
acxuuw00001177
08-10
NO GOOD
acxuuw00001178
NO GOOD NO GOOD
acxuuw00001595
08-10–5
1871-1U-06B(08-10).fm 6 ページ 2006年3月15日 水曜日 午前11時36分
NO GOOD
acxuuw00001180
Warning
• Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read the air bag system service warnings and cautions before handling the
air bag module. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-10-5 AIR BAG
SYSTEM SERVICE CAUTIONS.)
STOPPER
PLATE
acxuuw00000638
08-10–6
1871-1U-06B(08-10).fm 7 ページ 2006年3月15日 水曜日 午前11時36分
Warning
• Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read the air bag system service warnings and cautions before handling the
air bag module. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-10-5 AIR BAG
SYSTEM SERVICE CAUTIONS.)
• Due to the adoption of 2-step deployment control in the passenger-side air bag module,
depending on the impact force, it is possible that inflator No.2 might not deploy. In such cases,
before disposing of the air bag module, make sure to follow the inflator deployment procedures
and verify complete deployment of inflators No.1 and 2.
STOPPER
PLATE
acxuuw00000638
08-10–7
1871-1U-06B(08-10).fm 8 ページ 2006年3月15日 水曜日 午前11時36分
Warning
• Handling the air bag module improperly can accidentally operate (deploy) the air bag module,
which may seriously injure you. Read the air bag system service warnings and cautions before
handling the air bag module. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-10-5
AIR BAG SYSTEM SERVICE CAUTIONS.)
• If the side air bag module is installed with debris in the seat back, the foreign material may be
scattered when the side air bag module operates (deploys), causing injury. Verify that there is no
foreign material in the seat back before installing the side air bag module.
id081000800900
Warning
• Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read the air bag system service warnings and cautions before handling the
air bag module. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-10-5 AIR BAG
SYSTEM SERVICE CAUTIONS.)
08-10–8
1871-1U-06B(08-10).fm 9 ページ 2006年3月15日 水曜日 午前11時36分
3 4
TAB TAB
1 5
SEC. A—A
A
A
2 8.8—12.8 {89.8—130.5,
77.8—113.2} N·m {kgf·cm, in·lbf}
acxuuw00000641
1 Connector 4 Hook
(See 08-10-9 Connector Removal Note.) 5 Curtain air bag module
2 Bolt
3 Clip
08-10
5. Install in the reverse order of removal.
6. When the ignition switch is turned to the ON position verify that the air bag system warning light illuminates for
approx. 6 s and goes out.
• If the air bag system warning light does not operate normally, refer to the on-board diagnostic system (air
bag system) and perform inspection of the system.
STOPPER
PLATE
acxuuw00000638
08-10–9
1871-1U-06B(08-10).fm 10 ページ 2006年3月15日 水曜日 午前11時36分
Warning
• Handling the crash zone sensor improperly can accidentally deploy the air bags and pre-tensioner
seat belts, which may seriously injure you. Read the air bag system service warnings and cautions
before handling the crash zone sensor. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.)
(See 08-10-5 AIR BAG SYSTEM SERVICE CAUTIONS.)
Warning
• Handling the SAS control module improperly can accidentally deploy the air bag modules and pre-
tensioner seat belt, which may seriously injure you. Read the air bag system service warnings and
cautions before handling the air bag module. (See 08-10-3 AIR BAG SYSTEM SERVICE
WARNINGS.) (See 08-10-5 AIR BAG SYSTEM SERVICE CAUTIONS.)
• Connecting the SAS control module with the SAS control module not securely fixed to the vehicle
is dangerous. When the ignition switch is turned to the ON position, the SAS control module could
tilt causing the SAS control module to detect that the vehicle is in a rollover condition, which may
accidentally operate (deploy) the curtain air bag module and pre-tensioner seat belt. Therefore,
before turning the ignition switch to the ON position with the connector connected, securely fix
the SAS control module to the vehicle.
Caution
• Handling the SAS control module improperly can accidentally deploy the air bag modules and pre-
tensioner seat belt, which may seriously injure you. If configuration is not completed before
removing the SAS control module, DTC B2477 or B1017 will be displayed.
1. Perform SAS control module configuration when replacing it. (See 08-10-11 SAS CONTROL MODULE
CONFIGURATION.)
2. Turn the ignition switch to the LOCK position.
08-10–10
1871-1U-06B(08-10).fm 11 ページ 2006年3月15日 水曜日 午前11時36分
Caution
• When the seat weight sensor control module is replaced with a new one, perform the seat weight
sensor calibration using the M-MDS. (See 08-10-12 SEAT WEIGHT SENSOR CALIBRATION.)
1
acxuuw00000648
08-10–11
1871-1U-06B(08-10).fm 12 ページ 2006年3月15日 水曜日 午前11時36分
Caution
• If any of the following work is performed, perform the seat weight sensor calibration using the M-
MDS.
— Replacement with a new seat weight sensor
— Replacement with a new seat weight sensor control module
— Replacement with new passenger-side seat parts
— Disassembly of the passenger-side seat
• If any of the following work is performed, perform the seat weight sensor inspection using the M-
MDS. (See 08-10-12 SEAT WEIGHT SENSOR INSPECTION.)
— Removal of the passenger-side seat
— Loosening and retightening of passenger’s seat fixing bolts
— Or, the vehicle is involved in a collision
Caution
• If any of the following work is performed, perform the seat weight sensor inspection using the M-
MDS.
— Removal of the passenger-side seat
— Loosening and retightening of passenger’s seat fixing bolts
— Or, the vehicle is involved in a collision
• If any of the following work is performed, perform the seat weight sensor calibration using the M-
MDS. (See 08-10-12 SEAT WEIGHT SENSOR CALIBRATION.)
— Replacement with a new seat weight sensor
— Replacement with a new seat weight sensor control module
— Replacement with new passenger-side seat parts
— Disassembly of the passenger-side seat
08-10–12
1871-1U-06B(08-10).fm 13 ページ 2006年3月15日 水曜日 午前11時36分
Warning
• Handling the side air bag sensor improperly can accidentally operate (deploy) the air bag module,
which may seriously injure you. Read the air bag system service warnings and cautions before
handling the side air bag sensor. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-
10-5 AIR BAG SYSTEM SERVICE CAUTIONS.)
08-10–13
1871-1U-06B(08-10).fm 14 ページ 2006年3月15日 水曜日 午前11時36分
Warning
• Handling the side air bag sensor improperly can accidentally operate (deploy) the air bag module,
which may seriously injure you. Read the air bag system service warnings and cautions before
handling the side air bag sensor. (See 08-10-3 AIR BAG SYSTEM SERVICE WARNINGS.) (See 08-
10-5 AIR BAG SYSTEM SERVICE CAUTIONS.)
08-10–14
1871-1U-06B(08-10).fm 15 ページ 2006年3月15日 水曜日 午前11時36分
Note
• The adjustment procedure is also specified on the caution label of the clock spring.
08-10
1. Set the front tires straight-ahead.
Caution
• The clock spring will break if over-wound. Do not forcibly turn the clock spring.
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08-10–15
1871-1U-06B(08-10).fm 16 ページ 2006年3月15日 水曜日 午前11時36分
acxuuw00001598
Note
• When the vehicle-side connector for the clock spring is disconnected, terminals 1A, 1B, 1C and 1D are
shorted to prevent unexpected operation (deployment) of the air bag module.
: Continuity
Test Terminal
condi-
tion 1A 1B 1C 1D 2A 2B 2C 2D 2E 2G 2H 3A 3B 4A 4B 5A 5B 5C 5D 5E 5G 5H
Under
any
condi-
tion
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08-10–16
1871-1U-06B(08-10).fm 17 ページ 2006年3月15日 水曜日 午前11時36分
3A 3B 4A 4B 5A 5B 5C 5D 5E 5G 5H
A/B A/B A/B A/B CRUISE CRUISE ILLUMI- ILLUMI- AUDIO AUDIO
No.1 No.1 No.2 No.2 HORN
CONTROL CONTROL NATION NATION CONTROL CONTROL
+ - + - + - + - + -
1C 1D 1A 1B 2A 2B 2C 2D 2E 2G 2H
VEHICLE-SIDE CONNECTOR
1D 1C 1B 1A 2H 2G * 2E 2D 2C 2B 2A
3B 3A 4B 4A
5H 5G * 5E 5D 5C 5B 5A
acxuuw00001600
08-10
End Of Sie
AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DEPLOYMENT PROCEDURES
WM: AIR BAG MODULES
id081000801100
Warning
• A live (undeployed) air bag module or pre-tensioner seat belt may accidentally operate (deploy)
when it is disposed of and cause serious injury. Do not dispose of a live (undeployed) air bag
module and pre-tensioner seat belt. If the SSTs (Deployment tool and Adapter harness) are not
available, consult the nearest Mazda representative for assistance.
Caution
• Deploying the air bag modules and pre-tensioner seat belts inside the vehicle may cause damage
to the vehicle interior. When the vehicle is not to be scrapped, always deploy the air bag modules
and pre-tensioner seat belts outside the vehicle.
• If the vehicle is to be scrapped, or when disposing of any air bag modules or pre-tensioner seat belts, operate
(deploy) them inside the vehicle by following the deployment procedure below and using the SST (Deployment
tool).
• When disposing of an operated (deployed) air bag module and pre-tensioner seat belt, refer to “AIR BAG
MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL PROCEDURES”.