Rdce 08ma010 05 PDF

BULLETIN
CHASSIS
SAGA
Model YR 2011
English Edition RDCE-08MA010-05
Destination: MHR
August 2011 Printed in Malaysia
Copyright ©
Perusahaan Otomobil
Nasional Sdn. Bhd.
(Company No.: 100995-U)
Printed in Malaysia 24 August 2011 Eng
BULLETIN ALL
Group Index /I
00 OUTLINE OF CHANGES ............................................................... 00/1 - 00/14

11A ENGINE <IAFM +> .................................................................. 11A/1 - 11A/40
12 LUBRICATION ............................................................................... 12/1 - 12/2
13A FUEL .................................................................................... 13A/1 - 13A/180
15 INTAKE AND EXHAUST ............................................................... 15/1 - 15/17
21 CLUTCH ....................................................................................... 21/1 - 21/6
22 MANUAL TRANSMISSION ........................................................... 22/1 - 22/29
23 CVT .......................................................................................... 23/1 - 23/267
26 FRONT AXLE ............................................................................... 26/1 - 26/14
32 POWER PLANT MOUNT ................................................................ 32/1 - 32/9
35B ANTI-LOCK BRAKE SYSTEM (ABS) ........................................... 35B/1 - 35B/53
52B SUPPLEMENT RESTRAINT SYSTEM ......................................... 52B/1 - 52B/106
54 CHASSIS ELECTRICAL .................................................................... 54/1 - 54/4
55 HEATER, AIR CONDITIONER AND VENTILATION ............................. 55/1 - 55/9
All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.

ALL BULLETIN
/ II Group Index
NOTE

OUTLINE OF CHANGES 00
Content /1
00 OUTLINE OF CHANGES
OUTLINE OF CHANGES ............................................................... 00/2
DESCRIPTION ......................................................................... 00/2
RELATED PUBLICATION MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
TABLE OF CHANGE ITEMS & REFERENCE MANUALS ......................... 00/2
OUTLINE OF CHANGE ITEMS DETAIL ............................................ 00/4
VEHICLE IDENTIFICATION ............................................................ 00/10

MODEL ................................................................................ 00/10
4–Doors Sedan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/10
MODEL CODE ........................................................................ 00/10
TRANSMISSION MODEL AND SERIAL NUMBER ............................... 00/12
Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/12
Continuous Variable Transmission (CVT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/12
MAJOR SPECIFICATIONS ............................................................. 00/13

4–Door Sedan ........................................................................ 00/13

/2 OUTLINE OF CHANGES
OUTLINE OF CHANGES WCH000OLINE11003
DESCRIPTION
This bulletin is additional supplement to WORKSHOP MANUAL CHASSIS Pub. No.: RDWE-08MA010
(Basic) and RDWE-08MA010-03 (Bulletin) which contains only changes/updates/modification/additional
information due to the introduction of SAGA FLX model.
RELATED PUBLICATION MANUALS
The publications shown below are also available and should be used in conjunction with this manual
WORKSHOP MANUAL PUBLICATION NUMBER

ENGINE OVERHAUL RDWE-08OS4P020 (Basic)
RDCE-08OS4P020–03 (Bulletin IAFM+)
TRANSMISSION AND CLUTCH RDCE-11PNCH080–01 (BASIC CVT)
OVERHAUL RDCE-11GTRG080–01 (BASIC 5MTT200A)
ELECTRICAL WIRING RDWE-08MA030 (Basic)
RDWE-08MA030–01 (Bulletin 1.6 model)
RDWE-08MA030–02 (Bulletin NGV system)
RDCE-08MA030–03 (Bulletin Saga FL)
RDCE-08MA030–04 (Bulletin Saga IAFM+ & CVT)
FLAT RATE RDFE-08M040 (Basic)
RDFE-08M040–01 (Bulletin 1.6 & LHD model)
RDFE-08M040–02 (Bulletin NGV)
RDFE-08M040–03 (Bulletin Saga SE)
RDCE-08M040–04 (Bulletin Saga FL)
RDCE-08M040–05 (Bulletin IAFM+, CVT & 5MTT200A)
PDI & PERIODIC MAINTENANCE RDPE-08MA050 (Basic)
RDPE-08MA050–01 (Bulletin NGV)
RDCE-08MA050–02 (Bulletin IAFM+, CVT & 5MTT200A)
BODY REPAIR RDBE-08M060
TABLE OF CHANGE ITEMS & REFERENCE MANUALS
LEGEND:
: The symbol indicates item in which no change has been made and not in this supplement
manuals. The respective item should be referred to the respective manual (supplement or basic).
: The symbol indicates the item in which a change and/or addition has been made and the item
is presented in this supplement manual.
: The symbol indicates the information is not included in the respective manual (basic or supple-
ment)
RDWE- RDWE- RDWE- RDWE-
CLASSIFIC- RDWE- 08MA010–02 08MA010–03 08MA010–04 08MA010–05
MAIN TITLE
ATION 08MA010–01 (NEW BUL- (NEW BUL- (NEW BUL- (NEW BUL-
LETIN) LETIN) LETIN) LETIN)
GRP 00 – GENER-
–
AL
GRP 11 – ENGINE —
GRP 12 – LUBRICA-
—
TION
GRP 13A – FUEL —

OUTLINE OF CHANGES /3

MAIN TITLE
NGV Sys-
GRP 13E – NGV
tem
GRP 14 – COOL-
—
ING
GRP 15 – INTAKE
AND EXHAUST —
MANIFOLD
GRP 16 – ENGINE
—
ELECTRICAL
GRP 17 – EMIS-
—
SION CONTROL
GRP 21 – CLUTCH —
GRP 22 – MANU-
AL TRANSMIS- —
SION
GRP 23 – AUTO-
MATIC TRANSMIS- —
SION
GRP 23 – HY-
—
DRAULIC CIRCUIT
GRP 26 – FRONT
—
AXLE
GRP 27 – REAR
—
AXLE
GRP 31 – WHEEL
—
& TYRE
GRP 32 – POWER
—
PLANT MOUNT
GRP 33A – FRONT
—
SUSPENSION
GRP 34 – REAR
—
SUSPENSION
GRP 35 – SERVICE
—
BRAKES
GRP 35B – ABS —
GRP 36 – PARK-
—
ING BRAKES
GRP 37A – STEER-
—
ING
GRP 42 – BODY —
GRP 51 – EXTERI-
—
OR


MAIN TITLE
GRP 52A – INTERI-
—
OR
GRP 52B – SRS —
GRP 54 – CHASSIS
—
ELECTRICAL
GRP 55 – HEATER,
VENTILATION &
—
AIR-CONDITION-
ING SYSTEM
OUTLINE OF CHANGE ITEMS DETAIL
Change Items Reference Page Description Of Changes
GRP 00 – OUTLINE OF CHANGES
• VEHICLE IDENTIFICATION
• Includes description on model
— Model 00/10
code which fitted with Saga FLX
to 00/13
— Model Code model.
• MAJOR SPECIFICATIONS
GRP 11A–ENGINE <IAFM+>
• FEAD BELT DRIVE AND TV DAMPER • Update for new engine IAFM+
11A/3
PULLEY information on FEAD belt, Cylinder
to 11A/39
head & timing belt
— Removal and installation
• CYLINDER HEAD GASKET

— Removal service point
— Installation service points
• TIMING BELT
• ON-VEHICLE SERVICE
• ENGINE ASSEMBLY
GRP 12 – LUBRICATION
• GENERAL INFORMATION 12/2 • Update for new engine oil spe-
to 12/2 cification SAE 10W/30
• LUBRICATIONS
GRP 13A – FUEL • Update for new troubleshooting

13A/6
• GENERAL INFORMATION information for 32–bit ECU and
to 13A/168
IAFM+ engine.


• SERVICE SPECIFICATION
• TROUBLESHOOTING
—Engine warning lamp
—Freeze frame data
—Self diagnosis
—Inspection procedure for diagnosis
codes
—Inspection procedure for trouble
symptom
Dynamic data display
Actuator function
Check at Engine ECU
Inspection using an analyzer
GRP 15–INTAKE AND EXHAUST
• INTAKE MANIFOLD AND VACUUM •Update information for new
TANK ASSY 15/2 to 15/17 IAFM+ intake and catalytic system
— Removal and Installation design.
• INTAKE MANIFOLD
• INTAKE MANIFOLD AND VACUUM

TANK ASSY
— Removal and Installation
• INTAKE MANIFOLD
— Installation service point
• EXHAUST MANIFOLD
• EXHAUST PIPE AND MAIN MUFFLER
GRP 21– CLUTCH

• CLUTCH CONTROL (5MTT200A)
• Update information for new
— Removal service point 21/2 to 21/6 clutch design for 5MTT200A
— Installation service point (Getrag)
— Inspection
—On-vehicle service
GRP 22– MANUAL TRANSMISSION
• SPECIFICATION • Update information for new
— Gear ratio 22/2 to 22/21 manual transmission for 5MTT200A
— Lubricant (Getrag)
• SPECIAL TOOLS


• ON-VEHICLE SERVICE
— Differential seal
— Transmission oil level check
— Transmission oil replacement
• TRANSMISSION CONTROL
— Removal and Installation • Update information for new
— Removal service point 22/2 to 22/21 manual transmission for 5MTT200A
(Getrag)
• TRANSMISSION ASSEMBLE
GRP 23– CVT

• GENERAL INFORMATION
• SPECIFICATION • Update information for new
— General specification 23/8 to 23/258 Continuous Variable Transmission
— Service specification CVT (Punch)
— Lubricant
• SPECIAL TOOLS
• TROUBLESHOOTING
— Trouble code
• TROUBLE SYMPTOM
• DATA LIST
• CHECK AT CVT TCU CONNECTOR
• CHECK AT CVT CONNECTOR
• ON VEHICLE SERVICE
— CVT components location
— Shift cable adjustment
—Inspection procedures
— CVT fluid refill/ check
— CVT fluid replacement
— Oil level check
— Differential seal
— Primary cover
— Secondary cover
— Oil pump
— Primary ball bearing
— Oil pan & oil filter
— Drive mode sensor
— Hydraulic unit
— Secondary speed sensor and bracket
— Primary speed sensor
— Main connector and internal cable
harness


• TCU AND ECU
• CVT FLUID COOLER

— Removal service point 23/8 to 23/258 Continuous Variable Transmission
CVT (Punch)
• TRANSMISSION CONTROL
— Selector lever assy
• TRANSMISSION ASSEMBLY
• Update information for drive

shaft specification design due new
GRP 26– FRONT AXLE
Continuous Variable Transmission
• SPECIFICATION 26/2 to 26/10
CVT (Punch) and new manual
• SPECIAL TOOL
transmission for 5MTT200A
(Getrag).
• DRIVE SHAFT
— Removal service points
— Disassembly and reassembly < for
CVT transmission>
— Disassembly and reassembly < for
manual transmission>
— Disassembly service point
— Reassemble service point
GRP 32– POWER PLANT MOUNT
• ENGINE MOUNTING
32/2 to 32/6
— Removal service point IAFM+ engine.
• TRANSMISSION MOUNTING • Update information for transmis-

— Removal and Installation sion mounting design due new
Continuous Variable Transmission
— Removal service point CVT (Punch) and new manual
— Installation service point transmission for 5MTT200A
(Getrag).


GRP 35B– ANTI-LOCK BRAKE SYSTEM
• New information for ABS 9 sys-
• GENERAL INFORMATION 35B/4 to 35B/47
tem
Outline of changes
• SERVICE SPECIFICATION
• SPECIAL TOOL
• TROUBLESHOOTING
— Standard flow of diagnostic
Notes with regards to diagnosis
— ABS warning lamp
— Paring brake warning lamp
— Problem diagnosis content chart • New information for ABS 9 sys-
35B/4 to 35B/47
tem
— Inspection chart for diagnosis code
— Inspection chart for trouble symp-
tom
— Service data reference table
— Actuator function
— Inspection procedure using an ana-
lyzer
• ELECTRONIC HYDRAULIC CONTROL
UNIT
• WHEEL SPEED SENSOR


GRP 52B – SUPPLEMENTARY RE-
STRAINT SYSTEM
• GENERAL INFORMATION
• SRS SERVICE PRECAUTION
• SPECIAL TOOLS
• TEST EQUIPMENT
• PADT-II
• TROUBLESHOOTING
• Update information on
— Standard flow of diagnostic 52B/4 to 52B/105
ACU3–AP2 module variant
Troubleshooting
— Diagnosis function
— SRS warning lamp
— Dynamic display reference table
— Fault code reference table
— Front airbag (Driver’s side)
— Front airbag (Passesnger’s side)
— Pre tensioner (Driver’s side)
— Pre tensioner (Passenger side)
— Power and meter combination line
• SRS MAINTENANCE
— SRS warning lamp check
— SRS component visual check
— Instrument panel wiring harness /
floor wiring harness
• POST COLLISION DIAGNOSIS
— SRS-ECU memory check
— Repair procedure
• INDIVIDUAL COMPONENT SERVICE
• WARNING / CAUTION LABEL
• SRS ECU
• AIRBAG MODULE AND CLOCK
SPRING
• FRONT PASSENGER AIRBAG MODULE

/ 10 VEHICLE IDENTIFICATION

• AIRBAG MODULE AND SEAT BELT
PRE-TENSIONER DISPOSAL PROCEDURE
— General information
• SEAT BELT WITH PRETENSIONER

— Inspection
• UN-DEPLOYMENT AIRBAG MODULE 52B/4 to 52B/105 • Update information on
AND SEAT BELT PRE-TENSIONER DIS- ACU3–AP2 module variant
POSAL
— Deployment inside the vehicle
— Deployment outside the vehicle
— Inspection
• DEPLOYED AIR BAG MODULE OR
OPERATED SEAT BELT PRE-TENSIONER
DISPOSAL PROCEDURE
GRP 054 – CHASSIS ELECTRICAL
• COMBINATION METER
• Update information on ABS and
— Service specification 54/2 to 54/3
CVT .
— On-vehicle service
GRP 55– HEATER, AIR CONDITIONER

AND VENTILATION
• Refrigerant line
— Removal and installation • Update Saga FL refrigerant line
55/3 to 55/7
— Installation service point and compressor
• COMPRESSOR
VEHICLE IDENTIFICATION WCH000VIDEN11003
MODEL
4–Doors Sedan
Model code Engine model Transmission Fuel supply sys-
model tem
SNBYRMAD
SNSYRMAD 5MTT200A
S4PE DOCH (1332 cm³ (81.28
BT3 SNJYRMAD MPI
cu.in))
STSYRMAD
CVT 2(2WD - CVT)
STJYRMAD
MODEL CODE
1 2 3 4 5 6 7 8 9 10 11

VEHICLE IDENTIFICATION / 11
↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
B T 3 S R J F R M A D
No. Items Contents

1 Car segment B : Small / Super mini class
2 Platform T : TRM
3 Engine size 6 : S4PH–2–FDM DOHC (1597 cm³ (97.45 cu.in))
4 Body type L : 44 (4 – door hatchback)
S : 41 (4 – door sedan)
5 Transmission type N : 5 – Speed Manual Transmission
R : 4 – Speed Automatic Transmission
6 Grade of spec S : Low Line
J : M - Line
H : H - Line
7 Engine type E : MPI SOHC
M : MPI DOHC
W : MPI DOHC + IAFM + Bi-Fuel
F : MPI DOHC + IAFM
8 Steering Wheel Loca- R : RHD
tion L : LHD
9 Manufacturer M : PROTON
P : Zagros Khodro (Iran)
H : PT PTM Cikarang (Indo)
C : China
10 Destination A : Domestic
S : Australia
U : UK/EC
W : GCC
X : Extreme weather
11 Product life cycle O : Roll out (start of lifecycle)
A : Minor change (facelift 1)
B : Minor change (facelift 2)
C: Minor change (facelift 3)
D : Minor change (facelift 4)
E : Minor change (facelift 5)

/ 12 VEHICLE IDENTIFICATION
TRANSMISSION MODEL AND SERIAL

NUMBER
Manual transmission
The transmission number and the serial number
engraved are on the transmission case as shown
in the illustration
Symbol Description
A Transmission model number
B Transmission serial number
NOTE
Torch light is recommended to be used.
DOIMC000R11002
Continuous Variable Transmission (CVT)

The transmission number and the serial number
plate are on the transmission case as shown in
the illustration
Symbol Description
A Proton part number
B Transmission serial number
C Supplier part number
NOTE
Torch light is recommended to be used.
DOIMC000R11001

MAJOR SPECIFICATIONS / 13
MAJOR SPECIFICATIONS WCH000MSPEC11001
4–Door Sedan
DOIJC000R07001
BT3
Items / Model
SNBYRMAD SNSYRMAD SNJFRMAD STSYRMAD STJYRMAD
Overall length 1 4278 mm (168.42 in)
Overall width 2 1680 mm (66.14 in)
Overall height 3 1520 mm (59.84 in)
Wheelbase 4 2465 mm (97.05 in)
Front track 5 1446 mm (56.93 in)
Rear track 6 1446 mm (56.93 in)
Minimum running ground 7
150 mm (5.91 in) (Subframe front center)
clearance (Unladen)
Front overhang 8 869 mm (34.21 in)
Rear overhang 9 944 mm (37.17 in)
Weight 1067 kg
1024 kg 1030 kg 1040 kg 1057 kg
Kerb weight (10670 N,
(10240 N, (10300 N, (10400 N, (10570 N,
2352.74
2257.92 lbs) 2271.15 lbs) 2293.2 lbs) 2330.68 lbs)
lbs)

/ 14 MAJOR SPECIFICATIONS
BT3
Items / Model
SNBYRMAD SNSYRMAD SNJFRMAD STSYRMAD STJYRMAD
Gross vehicle weight 1427 kg
1384 kg 1390 kg 1400 kg 1417 kg
(14270 N,
(13840 N, (13900 N, (14000 N, (14170 N,
3146.54
3051.72 lbs) 3064.95 lbs) 3087 lbs) 3124.48 lbs)
lbs)
Max. axle weight
Front 850 kg (8500 N, 1874.25 lbs)
Rear 800 kg (8000 N, 1764 lbs)
Seating capacity 5
Engine
Model No. S4PE-2–FDA
Total displacement 1332 cm³ (81.28 cu.in)
Transmission
Model 5MTT200A CVT2
Type 5 – Speed manual transmission CVT
Fuel supply system Electronic controlled multipoint fuel injection

ENGINE <IAFM +> 11A
Content /1
11A ENGINE <IAFM +>

SPECIAL TOOLS ........................................................................ 11A/2
TOOLS ................................................................................. 11A/2
FEAD BELT DRIVE AND TV DAMPER PULLEY .................................... 11A/3

REMOVAL AND INSTALLATION ................................................... 11A/3
CYLINDER HEAD GASKET ........................................................... 11A/5

REMOVAL SERVICE POINTS ....................................................... 11A/7
INSTALLATION SERVICE POINTS .................................................. 11A/8
CAMSHAFT AND CAMSHAFT OIL SEAL ........................................... 11A/11

LUBRICATION POINTS .............................................................. 11A/13
REMOVAL SERVICE POINT ......................................................... 11A/15
TIMING BELT ........................................................................... 11A/19

INSTALLATION SERVICE POINTS ................................................. 11A/22
TIMING BELT / TIMING BELT TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/22
CRANKSHAFT OIL SEAL .............................................................. 11A/29

ENGINE ASSEMBLY ................................................................... 11A/35

INSTALLATION SERVICE POINT ................................................... 11A/40

11A ENGINE <IAFM +>
/2 SPECIAL TOOLS
SPECIAL TOOLS WCH11ASTOOL11001
TOOLS
Tool Number Name Use
Flywheel
EZT 0044 To lock flywheel .
Stopper
DOIME11AR11051
For vehicle diagnosis, ECU, Flashing,

PADT-II vehicle measurement and
EZT0047
VCI Kits troubleshooting — Refer to page
23/9 for details VCI kits & accessories.
DOIMC35BR11039

ENGINE <IAFM +> 11A
FEAD BELT DRIVE AND TV DAMPER PULLEY /3
FEAD BELT DRIVE AND TV DAMPER PULLEY WCH11ASASSY11001
REMOVAL AND INSTALLATION
DOIMC11AR07003
Pre-removal and Post-installation Operation

• Under Cover Removal and Installation.Refer to GROUP 032 — Power Plant Mount
Removal steps
1. Tensioner bolt
2. Tensioner bolt
3. Tensioner
4. FEAD belt
5. TV damper bolt
6. TV damper pulley
T1 : 4.8-5.2 kgm (48-52 Nm, 34.72-37.61 ft.lbs)
T2 : 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
T3 : 3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 120°± 4°

11A ENGINE <IAFM +>
/4 FEAD BELT DRIVE AND TV DAMPER PULLEY
DOIGC11AR03021
Fead belt route

1. Tensioner Accessory Drive pulley
2. TV damper pulley
3. Air-cond Compressor pulley
4. Power steering pump pulley
5. Water pump pulley — upper side
6. Alternator pulley
7. Water pump pulley — lower side

ENGINE <IAFM +> 11A
CYLINDER HEAD GASKET /5
CYLINDER HEAD GASKET WCH11ASASSY11002
DOIMC11AR11012

11A ENGINE <IAFM +>
/6 CYLINDER HEAD GASKET
Engine oil
Non-reusable
A: O-ring
B: Delivery pipe
• Fuel Discharge Prevention
• Engine Coolant Draining and Supplying (Refer to PUB. No RDWE-03DA010, GROUP 14 Cooling).
• Exhaust Manifold Removal and Installation (Refer to Group 15 ).
• Engine Oil Draining (Refer to GROUP 12).
• Timing Belt Removal and Installation
Removal steps
1. Bolt — (if fitted)
2. Engine Cover – (If fitted)
3. Plug top coil
4. Cam sensor
5. Throttle body connector and ignition coil connector
6. Cam cover
7. Cam cover seal
8. Control harness connector
9. Pressure regulator hose
10. Thermostat pipe assembly
11. Seal
12. Clip return hose
13. Thermostat return hose
14. Thermostat return hose
15. Knock sensor connector
16. Intake manifold stay bracket
17. Clamp hose
18. Front radiator hose upper
19. Cylinder head bolt
20. Cylinder head
21. Cylinder head gasket
22. Cylinder block
T1: 0.5-0.7 kgm (5-7 Nm, 3.62-5.06 ft.lbs)
T2: 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
T3: 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
T4: 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
T5: 4.8-5.2 kgm (48-52 Nm, 34.72-37.61 ft.lbs)
T6: 2.0 kgm (20 Nm, 14.47 ft.lbs) 4.0 kgm (40 Nm, 28.93 ft.lbs) 5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.2
kgm (2 Nm, 1.45 ft.lbs) + 60° + 60°

ENGINE <IAFM +> 11A
REMOVAL SERVICE POINTS WCH11ASPROC11001
POWER STEERING HOSE REMOVAL

Remove the power steering oil pump and
bracket assembly from the engine with the hose
attached.
NOTE
Place the removed power steering oil pump in a
place where it will not be a hindrance when re-
moving and installing the cylinder head assembly,
and tie it with a cord.
THERMOSTAT PIPE ASSEMBLY REMOVAL

1. Loosen the thermostat pipe assembly bolt
shown in the illustration.
2. Release return hose clip from cylinder head
Symbol Description
A Thermostat pipe assembly bolt
B Hose Clip
DOINE11AR11013
CYLINDER HEAD BOLT REMOVAL

Using the special tool, loosen the bolts in 2 or 3
steps in order of the numbers shown in the illus-
tration, and remove the cylinder head assembly.
CAUTION
Because the plug guides cannot be replaced by
themselves, be careful not to damage or deform
the plug guides when removing the cylinder
head bolts.
Symbol Description
A Special tool MB991653
TBS Timing belt side
DOIGC11AR03044

11A ENGINE <IAFM +>
/8 CYLINDER HEAD GASKET
INSTALLATION SERVICE POINTS

CYLINDER HEAD GASKET INSTALLATION
1. Wipe off all oil and grease from the gasket
mounting surface.
DOIGC11AR03045
2. Install so that the shapes of the cylinder head

holes match the shapes of the respective
cylinder head gasket holes.
Symbol Description
A Cylinder head
B Bushing
DOIMC11AR11002
CYLINDER HEAD BOLT INSTALLATION

1. When installing the cylinder head bolts,
check that the shank length (A) of each bolt
meets the limit. If the limit is exceeded, re-
place the bolt.
Limit:
Max. 160 mm (6.3 in) ± 0.35 mm (0.014 in)
2. Install the washers as illustrated.

3. Apply engine oil to the bolt threads and
washers.
DOIGE11AR03065

ENGINE <IAFM +> 11A
4. According to the tightening sequence as

shown in the illustration, tighten the bolts
to the specified torque.
Symbol Description
TBS Timing belt side
DOIGC11AR03048
TIGHTENING PROCEDURES (SERVICE) :

Steps Value Remarks
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.2
A
kgm (2 Nm, 1.45 ft.lbs)
4.0 kgm (40 Nm, 28.93 ft.lbs) ± 0.2
B
kgm (2 Nm, 1.45 ft.lbs) (1) One bolt at time.
5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.2 (2) Follow sequence No. 1 to 10 for steps
C A, B, & C.
kgm (2 Nm, 1.45 ft.lbs)
(3) Repeat each step until all bolts achieve
60° + 4° (Max)
D specification.
60° (Min)
60° + 4° (Max)
E
60° (Min)

11A ENGINE <IAFM +>
/ 10 CYLINDER HEAD GASKET
5. Give a 60° (refer table) turn to the cylinder

head bolts in the specified tightening se-
quence and give another 60° turn to the cyl-
inder head bolts.
Value
60° + 4° (Max)
60° (Min)
Symbol Description
1 Special tool MOT 591–04
CAUTION
DOIGC11AR03152
1. If the bolt is turned less than 60°, proper
fastening performance may not be expected.
When tightening the bolt, therefore, be careful
to give a sufficient turn to it.
2. If the bolt is overtightened, loosen the bolt
completely and then retighten it by repeating
the tightening procedure from step 1.
Value
60° + 4° (Max)
60° (Min)
THERMOSTAT PIPE ASSEMBLY

INSTALLATION
1. Apply a small amount of soap water to the
seal of the thermostat pipe assembly. Press
in to the water pump case assembly while
turning it left and right. Becareful not to
damage the seal. After installing, check that
the thermostat pipe assembly turns smoothly.
Symbol Description
A Thermostat pipe assembly
DOIHC11AR11003 B Seal
2. If the seal does not turn smoothly, the seal
is probably being clamped. Disconnected the
thermostat pipe assembly and check the seal
for damage. After this, re-insert the new
thermostat pipe assembly seal and repeat
procedure no.1.
Symbol Description
A Thermostat pipe assembly
B Seal in good fitting
C Front Seal
DOIGC11AR03051
D Impeller
E Water pump

ENGINE <IAFM +> 11A
CAMSHAFT AND CAMSHAFT OIL SEAL / 11
CAMSHAFT AND CAMSHAFT OIL SEAL WCH11ASASSY11006
DOIMC11AR11019

11A ENGINE <IAFM +>
/ 12 CAMSHAFT AND CAMSHAFT OIL SEAL
Sealant and Lubricant :

Part No. MD970389 or equivalent
Engine oil
Non-reusable
• Air Cleaner Removal and Installation (Refer to GROUP 15 — Air cleaner).
• Timing Belt Removal and Installation (Refer to page 11A/19 )
• Exhaust Manifold Removal and Installation (Refer to GROUP 15 — Exhaust Manifold).
• Water Hose and Water Pipe Removal and Installation (Refer to GROUP 14).
• Fuel discharged prevention (Refer to GROUP 13A — ON-VEHICLE SERVICE “Fuel Pressure Check”).
• Spark plug Removal and Installation (Refer to GROUP 16).
Removal steps
1. Bolt — * If fitted
2. Engine Cover — *If fitted
3. Top plug coil
4. Cam position sensor connector
5. Breather hose
6. Cylinder head cover
7. Camshaft sprocket
8. Camshaft sprocket
9. Camshaft oil seal inlet
10. Camshaft oil seal exhaust
11. Bearing cap
12. Bearing cap
13. Camshaft inlet
14. Camshaft exhaust
15. Tappet
T1 : 0.5 - 0.7 kgm (5 - 7 Nm, 3.62 - 5.06 ft.lbs)
T2 : 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
T3 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T4 : 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
T5 : 0.85 kgm (8.5 Nm, 6.15 ft.lbs) ± 0.05 kgm (0.5 Nm, 0.36 ft.lbs)
T6 : 3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 40° ± 2°

ENGINE <IAFM +> 11A
LUBRICATION POINTS
DOIMC11AR07006

11A ENGINE <IAFM +>
Symbol Description
A Camshaft Intake and Exhaust
B Engine oil
C Lip section
D Engine oil
E Sealant : Part No. MD970389 or equivalent
F Cylinder Head

ENGINE <IAFM +> 11A
REMOVAL SERVICE POINT WCH11ASPROC11006
CAMSHAFT SPROCKET REMOVAL

Use the special tool to remove camshaft sprocket.
DOIGC11AR03034
BEARING CAP CAMSHAFT REMOVAL

Loosen the bolt bearing cap in order as shown
in the illustration, and remove the bearing cap
in sequence as the number mark indicated.
Symbol Description
I Intake
E Exhaust
DOIGC11AR03150
TAPPET REMOVAL
Use magnetic tool to remove the tappet.
Symbol Description
I Magnet tool
DOIGE11AR03052
TAPPET INSPECTION
Check tappet by pressing the lash adjuster in the
tappet, if the lash adjuster is hard to press it
mean ‘‘a good condition’’. If the lash adjuster is
easily to press, it means the tappet is in ‘‘No
good condition’’. Replace with a new tappet.
Symbol Description
A Lash adjuster
Hard to press Good condition
Easy to press No good condition
DOIGE11AR03147

11A ENGINE <IAFM +>

CAMSHAFT INSTALLATION
1. Apply engine oil to journals and cams of the
camshafts.
2. Install the camshafts on the cylinder head.
Be careful not to confuse the intake camshaft
with the exhaust one. The inlet camshaft has
a notch on its rear end.
Symbol Description
A Camshaft sprocket side
DOIGC11AR03035
B Intake side camshaft
C Notch
BEARING CAP INSTALLATION

1. Set the camshaft dowel pins in the positions
as shown in the illustration.
Symbol Description
Intake camshaft dowel pin angle;
A
10°- 15° or 11 o'clock position
Exhaust camshaft dowel pin
B angle;
10°- 15° or 11 o'clock position
DOIGE11AR06180
NOTE
Place the notch for tightening the camshaft
head bolt in the correct position.
2. The bearing cap intermediate are the same
shape. Before they are installed, check the
cap number (B) and the intake and exhaust
identification marks (A).
Identification mark : (stamped on front and
intermediate bearing caps)
Mark (A) Description

I Intake side
E Exhaust side
1–5 Cap No. (B)
DOIGE11AR03056 NOTE
Make sure its arrow (C) is positioned on the
timing belt side.

ENGINE <IAFM +> 11A
3. Apply sealant on camshaft cap front area as

Symbol Description
A Cap front area
Specified sealant :
TB1110B 2 mm (0.079 in) bead size.
DOIGE11AR03055
4. Tighten bearing caps bolt to the specified

torque sequence.
Specified torque :
1.0 kgm (10 Nm, 7.23 ft.lbs)
Tightening sequence
1 3 5 7 9
Intake [I]
2 4 6 8 10
Exhaust 1 3 5 7 9
[E] 2 4 6 8 10
DOIGC11AR03040
NOTE
Don’t splash engine oil on the 1st. inlet and
exhaust camshaft cap cylinder head area.
CAMSHAFT OIL SEAL INSTALLATION

1. Apply minimum sufficient amount of engine
oil to oil seal housing and oil seal (A) lip.
2. Insert oil seal into the camshaft oil seal in-
staller (EZT 0006) by using the special
tool.Knock-in the oil seal carefully and slowly
Symbol Description
A Oil seal
Camshaft oil seal installer (EZT
DOIGC11AR03167 B
0006)
NOTE
Do not damage the oil seal,which will cause
malfunction of the oil seal.

11A ENGINE <IAFM +>
CAMSHAFT SPROCKET INSTALLATION

1. Locate the camshaft sprocket on the dowel
pin (1) on camshaft nose.
Symbol Description
A Dowel Pin
B Camshaft Intake Sprocket
C Camshaft Exhaust Sprocket
DOIME11AR11011
2. Use the special tool to hold the camshaft

sprocket from moving.
3. Tighten the camshaft sprocket bolt to the
specified torque.
Standard value :
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm,
1.45 ft.lbs) + 40° ± 2°
DOIGC11AR03034
CAM POSITION SENSOR INSTALLATION

Tighten the cam position sensor bolt to the spe-
cified torque.
Specified torque :
0.72 ft.lbs)
Symbol Description
A Cam position sensor
B Bolt
DOIME11AR11055

ENGINE <IAFM +> 11A
TIMING BELT / 19
TIMING BELT WCH11ASASSY11003
DOIMC11AR07031

• Disconnect Battery
• Remove undercover (RH)
• Engine Mounting Removal and Installation (Refer to Pub. No RDWE-03DA010, GROUP 32).
• Fead belt drive and TV damper Removal and Installation (Refer to page 11A/3 ).
• Power Steering Hose Removal and Installation (Refer to Pub. No RDWE-03DA010, GROUP 37A
— Power Steering Hoses).
• Support engine with crocodile jack.
Removal steps
1. Belt cover lower
2. TV damper pulley
3. Water pump pulley
4. Belt cover top
5. Engine Mounting Bracket
6. Timing belt tensioner
7. Timing belt
8. Crankshaft sprocket

11A ENGINE <IAFM +>
/ 20 TIMING BELT
T2 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T4 : 2.4 - 2.6 kgm (24 - 26 Nm, 17.36 - 18.81 ft.lbs)
T5 : 3.3 - 3.7 kgm (33 - 37 Nm, 23.87 - 26.76 ft.lbs)
T6 : 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)

ENGINE <IAFM +> 11A
TIMING BELT / 21
TIMING BELT / TIMING BELT TENSIONER

REMOVAL
1. Align camshaft sprocket timing marks ‘‘A’’
to features on cam cover ‘‘B’’ with the aid of
the cam sprocket alignment tool.
Symbol Description
A Camshaft sprocket timing marks
B Cam cover
C Align dowel
D Front case
DOIMC11AR11008
2. Align crankshaft to 90° ATDC (align dowel

’C’’ to one o’clock feature on front case’’D’’),
by using the special tool together with TV
damper bolt, turn the crankshaft sprocket
until get the actual align.
Symbol Description
C Align dowel
D Front case mark
E TV damper bolt
F Special tool - EZT 0007
DOIMC11AR11004

11A ENGINE <IAFM +>
/ 22 TIMING BELT
3. ‘‘STOP’’ the camshaft sprocket from turning

by inserting the special tool in between.
Symbol Description
1 Special tool - EZT 0004
DOIGC11AR03165
4. If the timing belt is to be reused, chalk an

arrow on the belt to indicate the direction
of rotation before removing it. This will en-
sure the timing belt is fitted correctly when
reused.
DOIGE11AR03020
5. Remove the timing belt tensioner, then pro-

ceed to remove the timing belt.
CAUTION
In order to remove the tensioner bolt, make
sure to use the correct single type socket box
because it can prevent the head bolt from
damage and wear
Symbol Description
A Single type socket box
B Ratchet
DOINE11AR11021 C Tensioner

WCH11ASPROC11003
TIMING BELT / TIMING BELT TENSIONER

INSTALLATION
1. Align camshaft sprocket timing marks (B)
with cam cover marks (A) and lock using
special tool EZT0004 (C) as shown in illustra-
tion.
NOTE :
Ensure that crankshaft is in safe position (90°
ATDC) for cylinder no.1.
DOIME11AR11017

ENGINE <IAFM +> 11A
TIMING BELT / 23
Symbol Description
A Sprocket marks
B Cam cover marks
C Special tool (EZT0004)
2. By using the special tool (EZT0007) align the
crankshaft sprocket to 90° ATDC (dowel pin)
“C” is aligned to “D” at one o'clock feature
on front case).
Symbol Description
C Crankshaft sprocket dowel
pin
D Front case marking
E TV damper bolt
DOIGE11AR03024
3. Fit tensioner bearing (A) by putting the foot

into the core plug (B) indent and ensuring
the allen key socket is positioned opposite
the foot as shown in illustration.
4. Then tighten tensioner bolt (C) by hand.
Symbol Description
A Tensioner bearing
B core plug
C Tensioner bolt
DOINE11AR11058
5. Before installing the reused timing belt,

make sure the arrow mark on top of the
timing belt is facing to the right direction.
DOIGE11AR03177

11A ENGINE <IAFM +>
/ 24 TIMING BELT
6. Firstly, fit timing belt halfway on to crank-

shaft sprocket and cam sprockets. Then fit
timing belt around tensioner pulley and push
belt fully onto all sprockets and pulley as
shown in illustration.
Caution:
Make sure (No slack along span 1 [S1] and
span 2 [S2] area.)
DOIME11AR11018
7. Turn the tensioner clockwise until pointer

indicator is exactly over the right hand side
edge of indicator notch (refer view B).
Tighten tensioner bolt whilst holding the al-
len key in place.
Specified torque :
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
DOIME11AR11019

ENGINE <IAFM +> 11A
TIMING BELT / 25
8. By using the special tool (EZT0007) with TV

damper bolt (E), rotate the engine twice
(720º crankshaft rotation). Ensure crankshaft
dowel pin (C) back aligned with front case
marks (D).
CAUTION :
Remove camshaft sprocket stopper from it
position before rotate.
DOIGE11AR03024
9. When the indicator stops within the nominal

position in the centre of the notch scale, the
belt is properly tensioner and task is com-
plete (refer view C).
DOIME11AR11020

11A ENGINE <IAFM +>
/ 26 TIMING BELT
10. If the indicator does not stop within the

nominal position, insert the allen key and
retain the installation shaft’s position on the
while loosening tensioner bolt with torque
wrench. Then using allen key slowly rotate
the installation shaft anti-clockwise until in-
dicator moves to free arm position as shown
on (view D).
DOIME11AR11021
11. Rotate tensioner bearing (1) clockwise until

the pointer is positioned in the centre of the
notch scale as shown on (view C)
12. Retighten tensioner bolt whilst holding the
allen key in place.
Specified torque :
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
DOIME11AR11022

ENGINE <IAFM +> 11A
TIMING BELT / 27
13. Rotate the crankshaft 720º until it reach to

safe point (90º ATDC)
14. CAUTION :
Remove camshaft sprocket stopper from it
position.
NOTE :
(1) Camshaft sprocket timing marks (A) are
aligned by cam cover timing marks (B).
(2) Crankshaft sprocket dowel pin (C) is
aligned with front case marks (D).
Symbol Description
A Camshaft sprocket timing
marks
B Cam cover marks
C Crankshaft sprocket dowel
pin
D Front case mark
DOIME11AR11023
15. If the indicator stops within the nominal po-

sition in the centre of the notch scale, the
belt is properly tensioned and the task is
complete. If the indicator does not stop in
the middle of the notch scale, then repeat
steps (10 until 14).
DOIME11AR11020

11A ENGINE <IAFM +>
/ 28 TIMING BELT
16. After checking the timing belt tension, insert

again the special tool EZT0004 (G) in
between of two camshaft sprockets in order
to make sure the camshaft sprocket “STOP”
from turning.
Symbol Description
G EZT0004
17. Then, turn TV damper bolt (T) anticlockwise
to loose TV damper bolt and special tool (U).
Remove TV damper bolt and special tool be-
fore installing timing belt cover.
DOIME11AR11013
Symbol Description
T TV damper bolt
U EZT0007
TIMING BELT LOWER COVER / UPPER COVER

INSTALLATION
1. Install timing belt lower cover (B) assy to en-
gine front cover lower side and tighten the
bolt flange.
Standard value (T1) :
0.9 -1.1 kgm (9 -11 Nm, 6.51 -7.96 ft.lbs)
2. Install timing belt upper cover (A) assy to

cylinder head front side and tighten the bolt
flange.
DOIME11AR11014 Standard value (T1) :
0.9 -1.1 kgm (9 -11 Nm, 6.51 -7.96 ft.lbs)

ENGINE <IAFM +> 11A
CRANKSHAFT OIL SEAL / 29
CRANKSHAFT OIL SEAL WCH11ASASSY11005
DOIMC11AR11018

11A ENGINE <IAFM +>
/ 30 CRANKSHAFT OIL SEAL
Sealant:
3M Stud locking 4170 or equivalent

Engine oil
• (A)- Crankshaft
• (B)- Engine oil bolt washer surface
• (C)- Lip section
Crankshaft front oil seal removal steps Crankshaft rear oil seal removal steps
• Timing belt (Refer to page 11A/19 ). • Transmission assembly
• Crank angle sensor (Refer to 11A — Oil Pan — (M/T: Refer to PUB. No RDWE-03DA010,
PUB. No RDWE-08MA010). GROUP 22)
1. Crankshaft sprocket (A/T: Refer to PUB. No RDWE-03DA011, GROUP
2. Crankshaft front oil seal 23)
• Clutch cover and disc <M/T>
3. Damper <CVT2>
bolt
4. Damper Assy <CVT2>
5. Flywheel Bolt
6. Flywheel Assy < 5TT200A>
7. Flywheel Assy <CVT2>
8. Crankshaft Bushing
9. Crankshaft rear oil seal.
T1 : 1.7 - 1.9 kgm (17 - 19 Nm, 12.3 - 13.74 ft.lbs)

ENGINE <IAFM +> 11A
DAMPER ASSY <CVT2> REMOVAL

1. Use the flywheel stopper to secure flywheel
, then remove the damper assy <CVT2> bolts
Symbol Description
A Flywheel assy <CVT2>
B Damper assy <CVT2>
C Flywheel stopper (EZT0044)
DOIME11AR11043 D Damper assy <CVT2> bolts
CLUTCH PLATE M/T <5MTT200A> REMOVAL

Refer to Chassis Workshop Manual Group 21C –
CLUTCH – Removal and Installation (RDCE –
08MA010 – 05)
FLYWHEEL ASSY <CVT2> REMOVAL

1. Use the flywheel stopper to secure flywheel,
then remove the flywheel bolts as shown in
the illustration.
Symbol Description
A Flywheel bolts
B Flywheel stopper (EZT0044)
C Flywheel assy <CVT2>
DOIME11AR11044
FLYWHEEL ASSY <5MTT200A> REMOVAL

1. Use the flywheel stopper to secure flywheel,
then remove the flywheel bolts as shown in
the illustration.
Symbol Description
A Flywheel stopper (EZT0044)
B Flywheel assy <5MTT200A>
C Flywheel bolts
DOIME11AR11045

11A ENGINE <IAFM +>

CRANKSHAFT REAR OIL SEAL INSTALLATION
1. Apply a small amount of engine oil to the
entire circumference of the oil seal lip.
2. Tap in the oil seal with the mallet as show in
the illustration.
Symbol Description
A Special tool EZT 0011
B Oil seal
C Crankshaft rear oil seal housing
D Mallet hammer
DRIVE PLATE <A/T> / FLYWHEEL <M/T> /

ADAPTER PLATE INSTALLATION
Use special tool to hold the flywheel or drive
plate in the same manner as removal, and install
the bolt.
DOIHC11AR04048
CRANKSHAFT FRONT OIL SEAL

INSTALLATION
1. Apply a small amount of engine oil to the
entire circumference of the oil seal lip.
2. Tap the oil seal unit until it is flush with the
oil seal case.
Symbol Description
A Crankshaft
B Oil seal
DOIIC11AR9032
REAR OIL SEAL CASE INSTALLATION

1. Apply liquid gasket to the rear oil seal case
at the illustrated position if it has no pre-
formed gasket attached.
Specified sealant :
Part No. MD970389 or equivalent (RTV seal-
ant, TREEBOND TB1207F).
CAUTION :
Squeeze the liquid gasket uniformly so that
there is no break in the gasket nor is there
DOIGE11AR03097 too much gasket.

ENGINE <IAFM +> 11A
2. Apply a suitable amount of engine oil to the

entire periphery of the oil seal lip and install
the oil seal on the cylinder block.
FLYWHEEL ASSY <5MTT200A> / FLYWHEEL

ASSY <CVT2> INSTALLATION
1. Clean off sealant, oil and deposits from the
threaded portion of the drive plate/adapter
plate tightening bolts and from the threaded
holes on the crankshaft.
2. Apply engine oil to the bolt flange and to
the threaded holes on the crankshaft.
3. Apply sealant to the treaded portion of the
bolt ( if the bolt is reused )
Specified sealant :
3M Nut Locking Part No. 4171 or equivalent
4. Install flywheel or drive plate to the crank-

shaft rear end as illustration and fit the bolt.
Symbol Description
1 Damper <CVT2> bolt
2 Damper assy <CVT2>
3 Flywheel bolt
4 Flywheel assy <5MTT200A>
5 Flywheel assy <CVT2>
6 Crankshaft bushing
7 Crankshaft rear oil seal
DOIME11AR11047
T1 1.7 - 1.9 kgm (17 - 19 Nm, 12.3
- 13.74 ft.lbs)

11A ENGINE <IAFM +>
5. Use the flywheel stopper (A), secure the fly-

wheel assy <CVT2> or flywheel assy
<5MTT200A> and tighten the bolts to the
specified torque.
Symbol Description
A Flywheel stopper (EZT0044)
B Flywheel assy <5MTT200A>
C Flywheel bolts
D Flywheel assy <CVT2>
T1 5.0 kgm (50 Nm, 36.16 ft.lbs) ±
0.2 kgm (2 Nm, 1.45 ft.lbs) + 60°
± 2°
T2 5.0 kgm (50 Nm, 36.16 ft.lbs) ±
0.2 kgm (2 Nm, 1.45 ft.lbs) + 30°
± 2°
DOIME11AR11048
DAMPER ASSY <CVT2> INSTALLATION

1. Use the flywheel stopper (C) to secure fly-
wheel, then tighten the damper assy <CVT2>
bolts (D) as shown in the illustration.
Symbol Description
A Flywheel assy <CVT2>
B Damper assy <CVT2>
C Flywheel stopper (EZT0044)
D Damper assy <CVT2> bolts
DOIME11AR11043
CLUTCH PLATE M/T <5MTT200A>
INSTALLATION
Refer to Group 21C – CLUTCH – Removal and In-
stallation

ENGINE <IAFM +> 11A
ENGINE ASSEMBLY / 35
ENGINE ASSEMBLY WCH11ASASSY11004
DOIMC11AR07034

11A ENGINE <IAFM +>
/ 36 ENGINE ASSEMBLY
Pre-removal Operation
• Transmission Removal (Refer to page22/21 for MT and page 23/258 for CVT)
• Fuel discharge Prevention (Refer to Pub. No RDWE-03DA011, GROUP 13A)
• Draining Radiator Coolant (Refer to Pub. No RDWE-03DA010, GROUP 14)
• Hood Removal (Refer to Pub. No RDWE-03DA010, GROUP 42)
• Air Cleaner Removal (Refer to page GROUP 15)
• Radiator Removal (Refer to page GROUP 14)
• Front Exhaust Pipe Removal (Refer to Pub. No RDWE-03DA010, GROUP 15)
• Remove undercover LH/RH
Post-installation Operation
• Transmission Removal (Refer to page22/21 for MT and page 23/258 for CVT)
• Fuel discharge Prevention (Refer to Pub. No RDWE-03DA011, GROUP 13A)
• Front Exhaust Pipe Installation (Refer to Pub. No RDWE-03DA010, GROUP 15)
• Radiator Installation (Refer to page GROUP 14)
• Air Cleaner Installation (Refer to page GROUP 15)
• Hood Installation (Refer to GROUP 42)
• Fead Belt Tension Adjustment (Refer to GROUP 11)
Removal steps 17. Map sensor
1. Batttery negative (-) cable 18. Coolant temperature sensor
2. Battery positive (+) cable 19. Alternator B
3. Pulse generator B (A/T) 20. Alternator S
4. ELC4 solenoid assy (A/T) 21. Knock sensor connector
5. Inhibitor switch 22. Oil pressure switch
6. Back-up switch (M/T) 23. Purge solenoid valve
7. Pulse generator A (A /T) 24. Ignition coil connector
8. Earth cable 25. Harness battery to harness control
9. Ignition coil 26. Inhibitor switch
10. Starter B 27. Back-up switch
11. Starter S
12. Injector connector
13. Crank angle sensor
14. Cam angle sensor
15. Harness control
16. Harness control to sub-harness sensor

ENGINE <IAFM +> 11A
DOIMC11AR11016

11A ENGINE <IAFM +>
• Hang on engine to engine hanger until there is no weight on the engine mount bracket insulator.
• Engine cover removal and installation
Removal steps
31. Power steering hose mounting bolt
32. A/C Compression hose mounting bolt
33. Power steering pressure line from power steering pump
34. Power steering feeding line from power steering pump
35. Radiator lower hose connection
36. Radiator upper hose connection
37. Heater flow hose connection – (if fitted)
38. Heater return hose connection – (if fitted)
39. A/C lines from compressor
40. Engine mounting bolt
41. Engine mounting nut
42. Engine insulator mounting bolt
43. Engine mounting bracket
44. Engine mounting stopper
CAUTION
Mounting location marked by * should be provisionally tightened, and then fully tightened
when the body is supporting the full weight of the engine.
T1: 0.9 - 1.4 kgm (9 - 14 Nm, 6.51 - 10.13 ft.lbs)
T2: 5.0 - 6.4 kgm (50 - 64 Nm, 36.16 - 46.29 ft.lbs)
T3: 9.0 - 11.0 kgm (90 - 110 Nm, 65.1 - 79.56 ft.lbs)
T4: 4.2 - 4.4 kgm (42 - 44 Nm, 30.38 - 31.83 ft.lbs)
T5: 1.5 - 2.5 kgm (15 - 25 Nm, 10.85 - 18.08 ft.lbs)

ENGINE <IAFM +> 11A
ENGINE MOUNT INSULATOR MOUNTING

BOLT / POWER STEERING BRACKET MOUNTING
BOLTS AND LINE MOUNTING
1. To make it easier to remove the engine as-
sembly, remove the power steering pressure
line complete from engine mount bracket
and power steering pressure pump.
2. Remove the power steering hose clamp
mounting bolt.
3. Remove the power steering pressure line
from power steering pressure pump.
4. Remove the engine mount damper mounting
nut.
Symbol Description
A Power steering pressure line
B Power steering pressure line screw
joint
C Power steering pressure pump
DOIHC032R04004
REMOVAL SERVICE POINTS

ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and harness
connectors, etc., are disconnected from the en-
gine, lift the chain block slowly to remove the
engine assembly upward from the engine com-
partment.
Symbol Description
A Engine lifting link
DOIHC022R04002

11A ENGINE <IAFM +>
INSTALLATION SERVICE POINT

ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, check all the cables,
hoses, and harness connectors are properly
clamped.
HIGH-PRESSURE FUEL HOSE INSTALLATION

1. Apply a small amount of new engine oil to
the O-ring.
DOIMC11AR07002
CAUTION
Do not let any engine oil get into the deliv-
ery pipe.
2. While turning the fuel high-pressure hose to
the right and left, install it to the delivery
pipe, while being careful not to damage the
O-ring. After installing, check that the hose
turns smoothly.
3. If the hose does not turn smoothly, the O-
ring is probably being clamped. Disconnect
the high-pressure fuel hose and check the O-
ring for damage. Then, insert back the deliv-
ery pipe and check that the hose. Ensure the
hose turns smoothly.

LUBRICATION 12
Content /1
12 LUBRICATION
GENERAL INFORMATION ........................................................... 12/2
ENGINE OILS ......................................................................... 12/2
Health Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/2
Recommended Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/2
LUBRICATIONS ......................................................................... 12/2

LUBRICANTS ......................................................................... 12/2

12 LUBRICATION
/2 GENERAL INFORMATION
GENERAL INFORMATION WCH012GINFO006
The lubrication method is a fully forced-fed, full-flow filtration type. The oil pump is a trochoid type
which is directly mounted to the crankshaft. Furthermore, the oil pressure sensor is located at the
cylinder block and a system is equipped whereby an indicator gives a warning when the oil level drops.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially
harmful contaminations which may cause skin cancer. Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working practices which prevent, as far as practicable, the
risk of skin contact with mineral oil, for example by using enclosed systems for handling used engine
oil and by degreasing components where practicable, before handling them.
Other precautions:
• Avoid prolonged and repeated contact with oils, particularly used engine oils.
• Wear protective clothing, including impervious gloves where practicable.
• Avoid contaminating clothes, particularly underpants, with oil.
• Do not put oily rags in pockets, the use of overalls without pockets will avoid this.
• Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned
regularly and kept separate from personal clothing.
• Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles
or face shields; in addition an eye wash facility should be provided.
• Obtain First Aid treatment immediately for open cuts and wounds.
• Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin
cleansers and nail brushes will help). After cleaning, the application of preparations containing
lanolin to replace the natural skin oils is advised.
• Do not use petrol , kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin.
• Use barrier creams, applying them before each work period, to help the removal of oil from the
skin after work.
• If skin disorders develop, obtain medical advice without delay.
LUBRICATIONS WCH012SPECS11001
LUBRICANTS
Items Engine oil (API classification) Quantity
Approx : 0.3 lit (0.32 U.S.qts,
Oil filter
0.26 Imp.qts)
SAE 20W/50 or equivalent ‘‘SERVICE SJ
Total quantity
’’ or higher
Approx : 3.75 lit (3.95 U.S.qts,
1300/1600
3.26 Imp.qts)

FUEL 13A
Content /1
13A FUEL
GENERAL INFORMATION ............................................................ 13A/6
OUTLINE OF CHANGES ............................................................. 13A/6
GENERAL SPECIFICATION .......................................................... 13A/6
SERVICE SPECIFICATION ............................................................. 13A/6

SEALANT .............................................................................. 13A/7
SPECIAL TOOLS ........................................................................ 13A/7
TROUBLESHOOTING .................................................................. 13A/8

FREEZE FRAME DATA ............................................................... 13A/8
DISPLAY ITEM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/9
FAIL-SAFE/BACKUP FUNCTION TABLE ........................................... 13A/10
READ OUT OF MALFUNCTION CODE ........................................... 13A/10
PRECAUTION FOR OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/10
CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS ....................... 13A/11
ENGINE WARNING LAMP .......................................................... 13A/13
ITEMS INDICATED BY THE ENGINE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/13
ENGINE WARNING LAMP INSPECTION .......................................... 13A/14
SELF-DIAGNOSIS ..................................................................... 13A/14
PADT- II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/14
PROBLEM DIAGNOSIS CONTENT CHART- IAFM+/ CFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/15
INSPECTION CHART FOR DIAGNOSIS CODES .................................. 13A/24
INSPECTION PROCEDURE FOR DIAGNOSIS CODES ............................. 13A/29

CAMSHAFT SENSOR ................................................................ 13A/29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/29
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/30
TROUBLESHOOTING OF FRONT OXYGEN SENSOR ........................... 13A/31
TROUBLESHOOTING OF REAR OXYGEN SENSOR ............................. 13A/34
THROTTLE BODY ACTUATOR ..................................................... 13A/37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/37
TMAP SENSOR (INTAKE AIR TEMPERATURE SENSOR AND VACUUM 13A/42
SENSOR) ...............................................................................
OPERATION INTAKE AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/42
OPERATION FOR VACUUM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/43
COOLANT TEMPERATURE SENSOR .............................................. 13A/46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/46
ACCELERATOR PEDAL SENSOR ................................................... 13A/49
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/49
OXYGEN CONTROL ................................................................. 13A/51
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/51
INJECTORS ............................................................................ 13A/54
FUEL PUMP RELAY .................................................................. 13A/57
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/57
MISFIRE ............................................................................... 13A/59
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/59

13A FUEL
/2 Content

KNOCK SENSOR ..................................................................... 13A/62
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/62
CRANKSHAFT SENSOR ............................................................. 13A/65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/65
TROUBLESHOOTING PROSEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/66
IGNITION COIL ....................................................................... 13A/67
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/68
CATALYTIC SYSTEM ................................................................. 13A/69
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/69
CANNISTER PURGE SOLENOID VALVE .......................................... 13A/71
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/71
ENGINE FAN .......................................................................... 13A/74
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/74
VEHICLE SPEED SIGNAL [ A/T ] ................................................... 13A/76
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/76
VEHICLE SPEED SIGNAL [ M/T ] ................................................... 13A/79
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/79
BRAKE LIGHT SWITCH (Stop lamp switch) ..................................... 13A/82
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/83
ENGINE SPEED SIGNAL [ A/T ] .................................................... 13A/84
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/84
ENGINE SPEED SIGNAL [ M/T ] .................................................... 13A/87
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/87
IMMOBILISER ........................................................................ 13A/90
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/90
POWER SUPPLY ...................................................................... 13A/92
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/93
ENGINE CONTROL UNIT ........................................................... 13A/94
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/94
STARTER CONTROL ................................................................. 13A/96
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/96
SENSOR SUPPLY ..................................................................... 13A/98
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/98
AIR COND CLUTCH .................................................................. 13A/101
VIM (VACCUM ACTUATOR) [IAFM] .............................................. 13A/104
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/104
MAIN RELAY ......................................................................... 13A/106
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/107
TRANSMISSION CONTROL UNIT (CVT) .......................................... 13A/109
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/109
P/N SWITCH .......................................................................... 13A/111
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/111

FUEL 13A
Content /3

PEDAL/BRAKE SWITCH ............................................................. 13A/113
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/114
CAN COMUNICATION .............................................................. 13A/116
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/116
TROUBLE SYMPTOM ................................................................. 13A/118

INSPECTION CHART FOR TROUBLE SYMPTOMS .............................. 13A/118
PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) ................. 13A/120
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS ......................... 13A/121

INSPECTION PROCEDURE 1 ....................................................... 13A/121
Communication with PADT-II is not possible (Communication with all systems is not 13A/121
possible ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PADT-II Communication with engine-ECU is impossible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/121
The engine warning lamp does not illuminate right after the ignition switch is turned 13A/122
to the ON position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The engine warning lamp remains illuminating and never goes out. . . . . . . . . . . . . . . . . . 13A/123
No initial combustion (starting impossible) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/124
Initial combustion but no complete combustion (starting impossible) . . . . . . . . . . . . . . . . 13A/125
Takes too long time to start (Incorrect Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/126
Unstable idling (Rough idling, hunting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/127
Idling speed is high (Improper idling speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/128
INSPECTION PROCEDURE 10 ...................................................... 13A/129
Idling speed is low (Improper idling speed ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/129
When the engine is cold, it stalls at idling (Die out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/130
When the engine is hot, it stalls at idling (Die out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/131
The engine stalls when starting the car (Pass out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/132
The engine stalls when decelerating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/133
Hesitation, sag or stumble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/134
The feeling of impact or vibration when accelerating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/135
The feeling of impact of vibration when decelerating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/136
Poor acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/137
Surge ................................................................................. 13A/138
Knocking ............................................................................. 13A/139
Dieseling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/140
Too high CO and HC concentration when idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/141

13A FUEL
/4 Content

Low Alternator Output Voltage (Approx 12.3 V ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/142
Power supply system and ignition switch-IG system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/142
Fuel pump system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/143
Ignition switch-ST system [M/T] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/144
Ignition switch-ST and inhibitor switch system [CVT] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/145
A/C switch and A/C relay system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/146
Fan motor relay system (Radiator fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/147
Tank purge valve system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/148
PADT-II: Inspection of no initial combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/149
Ignition system: Inspection of no initial combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/150
PADT-II: Check if incomplete combustion occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/151
Check if hunting occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/152
PADT-II: Check if idling speed is unstable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/153
PADT-II : Engine stalling inspection when the engine is warmed up and idling . . . . . . . 13A/154
PADT-II: Check if hesitation, sug, stumble or poor acceleration occurs . . . . . . . . . . . . . . . . 13A/155
PADT-II: Check if surge occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/156
Check the engine-ECU power supply and earth circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/157
Check fuel pump motor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/158
Check the fuel pump relay drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/159
Check throttle body actuator (TBA) output circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/160
Check injector control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/161
Check ignition coil and power transistor unit circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/162
DATA LIST ............................................................................... 13A/163

DATA LIST REFERENCE TABLE ..................................................... 13A/163
ACTUATOR TEST ...................................................................... 13A/166

ACTUATOR TEST REFERENCE TABLE ............................................ 13A/166
CHECK AT THE ENGINE-ECU ........................................................ 13A/168

TERMINAL VOLTAGE CHECK CHART ............................................ 13A/168
ENGINE-ECU CONNECTOR TERMINAL ARRANGEMENT ..................... 13A/169
CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMIN- 13A/172
ALS .....................................................................................
ECU ...................................................................................... 13A/174

FUEL 13A
Content /5

INJECTOR ............................................................................... 13A/177

INSTALLATION SERVICE POINT ................................................... 13A/177
INJECTOR/HIGH-PRESSURE FUEL HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/177

13A FUEL
GENERAL INFORMATION WCH13AGINFO11001
OUTLINE OF CHANGES
Due to the introduction of engine IAFM+ variant, the service procedure for the fuel system has been
updated.
GENERAL SPECIFICATION WCH13AGINFO11002
IAFM+
Item Specification
Throttle bore mm 50 mm (1.97 in)
Throttle position sensor Variable resistor type
Stepper motor type (Stepper motor type
Throttle body Idle speed control servo by-pass air control system with the air
volume limiter)
Rotary contact type, within throttle posi-
Idle position switch
tion sensor
Engine-ECU Identification model No. 32–bit
Vacuum sensor (Manifold absolute
Semiconductor type
pressure sensor)
Intake air temperature sensor /
Thermistor type
Pressure sensor
Engine coolant temperature sensor Thermistor type
Sensor Oxygen sensor Zirconia type
Vehicle speed sensor Magnetic resistive element type
Inhibitor switch Contact switch type
Crank angle sensor Hall element type
Camshaft sensor
Knock sensor
Control relay type Contact switch type
Fuel pump relay Contact switch type
Injector type and number Electromagnetic type, 4
Actuators
Injector identification mark CDH210
EGR control solenoid valve ON/OFF type solenoid valve
Purge control solenoid valve ON/OFF type solenoid valve
Fuel pressure regulat-
Regulator pressure kPa 329
or (low pressure)
Fuel pressure regulat-
Regulator pressure MPa 5
or (high pressure)
SERVICE SPECIFICATION WCH13ASPECS11002
IAFM+
Items Specifications
Basic idle speed r/min 750 r/min ± 100 r/min
Idle speed when A/C is ON r/min 850 r/min at neutral position
Throttle position sensor adjusting voltage mV 400 - 1000 mv

FUEL 13A
SPECIAL TOOLS /7
Throttle position sensor resistance kΩ 3.5 - 6.5 kΩ
Idle speed control servo coil resistance Ω 28 - 33 Ω (at 20 °C (68 °F))
Intake air temperature sensor resistance 20 °C (68 °F) 2.3 - 3.0 kΩ
kΩ 80 °C (176 °F) 0.30 - 0.42 kΩ
Engine coolant temperature sensor res- 20 °C (68 °F) 2.1 - 2.7 kΩ
istance kΩ 80 °C (176 °F) 0.26 - 0.36 kΩ
Oxygen sensor output voltage V 0.6 - 1.0 V
Fuel pressure kPa Vacuum hose discon- 324 - 343 kPa (46.09 - 48.8 psi, 97.81
nection - 103.54 in.Hg) at curb idle
Vacuum hose connec- Approx. 265 kPa (37.7 psi, 80 in.Hg)
tion at curb idle
Injector coil resistance Ω 13 - 16 Ω (at 20 °C (68 °F))
SEALANT
Item Specified sealant Remark
Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equival- Drying sealant
threaded portion ent
SPECIAL TOOLS WCH13ASTOOL11001
TOOLS
Vehicle communication
EZT0047 For vehicle diagnosis
interface (VCI)
DOIMC35BR11039
VCI manager software

CD for software installa-
and user documentation
tion and user manual
CD
DOIMC35BR11042
DLC cable (16-pin OBD Main diagnosis cable to

connector; 1 m) VCI
DOIMC35BR11041

13A FUEL
/8 TROUBLESHOOTING
For connection between

USB cable (1.8 m)
PC and VCI
DOIMC35BR11046
Power supply without To power-up VCI from

plug adapters power socket
DOIMC35BR11045
For software to download-

Ethernet cable
ing to VCI
DOIMC35BR11040
To tie-up cable and avoid

Cable keeper
cable messy
DOIMC35BR11043
Plug adapter for power To be use with power sup-

supply ply (EZT 0050)
DOIMC35BR11044
VCI storage case Bag to carry set of PADT-II
DOIMC35BR11047
TROUBLESHOOTING WCH13ASHOOT11032
FREEZE FRAME DATA

When the engine-ECU detects a malfunction and stores a diagnosis code, it also stores a current status
of the engine. This function is called "Freeze frame data". By analyzing this "Freeze frame" data with
the PADT.-II, an effective troubleshooting can be performed.
The display items of freeze frame data are shown below.

FUEL 13A
TROUBLESHOOTING /9
DISPLAY ITEM LIST

No PADT-II Display Unit / Condition Remarks
1 Fuel system status • Open Loop*1 *1– Condition in which oxygen sensor sig-
• Close Loop*2 nals are fed back to the engine-ECU for
• Open loop in- controlling fuel.
terrupt *2– Condition in which fuel is controlled
• Open loop er- without oxygen sensor signals being fed
ror*3 back to the engine-ECU because the condi-
• Closed loop er- tion to shift to the closed loop is not met.
ror*4 *3– Condition of open loop due to system
failure
*4– Condition of closed loop only using
front oxygen sensor when rear oxygen
sensor is failed
2 Relative engine load value %
3 Engine coolant temperature °C
4 Lambda controller output %
5 Fuel mass set point factor %
6 Manifold absolute pressure kPA
7 Engine speed rpm
8 Vehicle speed km/h
9 Front Oxygen Sensor Status OFF / ON
10 Rear Oxygen Sensor Status OFF / ON
11 Short Term Secondary O2 %
Sensor Fuel Trim
12 Long Term Secondary O2 %
Sensor Fuel Trim
13 DTC Failure byte -
14 Fuel system status • Open Loop*1 *1– Condition in which oxygen sensor sig-
• Close Loop*2 nals are fed back to the engine-ECU for
• Open loop in- controlling fuel.
terrupt *2– Condition in which fuel is controlled
• Open loop er- without oxygen sensor signals being fed
ror*3 back to the engine-ECU because the condi-
• Closed loop er- tion to shift to the closed loop is not met.
ror*4 *3– Condition of open loop due to system
failure
*4– Condition of closed loop only using
front oxygen sensor when rear oxygen
sensor is failed
15 Relative engine load value %
17 Fuel mass set point factor %
18 Lambda controller output %
19 Manifold absolute pressure kPA
20 Vehicle speed km/h
21 Engine speed rpm
22 Relative throttle position %

13A FUEL
/ 10 TROUBLESHOOTING
No PADT-II Display Unit / Condition Remarks

23 Ignition factor applier on first °CRK
cylinder
24 Engine status • Idle mode, idle
contact closed
• Full load mode
• SAS active
• Throttle actuat-
or limp home
mode
• Safety concept
activated
• Fuel Shut off
mode
25 Time after start s Accumulated time of current malfunction
from time point when malfunction is detec-
ted
26 Fault status byte MIL On / MIL Off
27 Number of DTC since last DTC -
clear command
28 Distance since DTC clearing km
29 Safety level 2 monitoring data - normal value = 0
30 Safety level 2 monitoring data If display is different from normal value,
replace ECU.
31 Safety level 2 monitoring data
32 Safety level 2 monitoring data
FAIL-SAFE/BACKUP FUNCTION TABLE WCH13ASHOOT11025
When the main sensor malfunctions are detected by the self-diagnosis function, the vehicle is controlled
by means of the pre-set control logic to maintain safe conditions for driving.
Malfunction item Control contents during malfunction

Intake air temperature sensor Controls as if the intake air temperature is 40 °C (104 °F)
Coolant temperature sensor Controls as if the coolant temperature is 80 °C (176 °F)
No increase in fuel injection amount during acceleration due
Throttle body actuator (TBA)
to the throttle position sensor signal
1. Injects fuel into the cylinders in the order 1-3-4-2 with
irregular timing (However, after the ignition switch is
Camshaft sensor
turned to ON, the No. 1 cylinder top dead center is not
detected at all)
Combined map & mat sensor Use TPS signal as back-up
Air/Fuel ratio feedback control (closed loop control) is not
Oxygen sensor
performed
READ OUT OF MALFUNCTION CODE
PRECAUTION FOR OPERATING
1. When battery voltage is low, no detection
of failure is possible. Be sure to check the
battery for voltage and other conditions be-
fore starting the tests.

FUEL 13A
TROUBLESHOOTING / 11
2. Connection and disconnection of the PADT–II

should always be made with the ignition
switch in the OFF position.
3. Fault code can only be erased when ignition
switch is in the ON position. After deleting
switch to “OFF” position and wait 30 sec.
before turning ⇒ “ON” the ignition.
READING PROCEDURE — USING PADT–II

1. Read and make a note of the self-diagnosis
output.
2. Repair the problem location, referring to the
diagnosis chart.
3. After turning the ignition switch once to OFF,
turn it back to ON.
4. Erase the malfunction code.
5. Recheck to be sure that the condition is nor-
mal.
Symbol Description
DOIMC13AR11111
PADT-II vehicle commu-
A
nication interface ( VCI )
B OBD-II cable
C USB cable
NOTE
For details information on the PADT-II, please
refer to the PADT-II User Manual.
CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS
Problem
Stoppi-
symp- Starting Idling stability Driving
ng
toms
Idling
Impr- Run-
Start- insta- Incor- Hes- Poor
Will oper on
ing bility rect id- ita- accel- Stum- Sho- Sur- Knoc-
not idling (Dies-
pro- (Rou- ling tion, era- ble ck ge king
start conti- el-
blem gh id- speed sag tion
nuity ing)
ling)
Power
∇1
supply/
#1
diode
Engine
control
∇2
unit
#2
power
earth
Fuel ∇3 ∇1 ∇1 ∇1 ∇1
pump #3 #1 #1 #1 #1

13A FUEL
Problem
Stoppi-
ng
toms
Intake
air tem-
pera-
∇5 ∇4 ∇2
ture ∇5
#5 #4 #2
sensor –
Mat
sensor
Vacuum
sensor
(Mani-
fold ab-
∇8 ∇6 ∇3
solute ∇7
#8 #6 #3
pressure
sensor –
Map
sensor
Coolant
tem-
∇6 ∇1 ∇5 ∇7 ∇5 ∇4 ∇3
pera- #3
#5 #1 #5 #7 #5 #4 #3
ture
sensor
Cam-
∇5 ∇5 ∇8 ∇2
shaft
#5 #6 #7 #2
sensor
Crank-
∇6 ∇6 ∇9 ∇3
shaft
#6 #7 #8 #3
sensor
Ignition
∇4 ∇3
switch-
#4 #4
ST (M/T)
Ignition
switch-
ST and
∇4 ∇3
inhibit- ∇3
#4 #4
or
switch
(A/T)
Acceler-
ator ∇3 ∇4 ∇4 ∇5
Pedal #3 #2 #4 #5
Sensor
Vehicle
speed ∇6 ∇6
sensor

FUEL 13A
Problem
Stoppi-
ng
toms
Air con-
ditioner
switch
∇2
and
power
relay
Oxygen
∇10
sensor
Throttle
∇4 ∇1 ∇5 ∇2 ∇6 ∇3 ∇4
body ac-
#5 #1 #3 #2 #6 #3 #4
tuator
Inject- ∇8 ∇2 ∇2 ∇3 ∇2 ∇2 ∇1 ∇1 ∇1
ors #8 #2 #2 #3 #2 #2 #1 #1 #1
Ignition ∇7 ∇10 ∇7 ∇1 ∇4
coil #7 #9 #7 #1 #4
Knock ∇1
sensor #1
Tank
∇4 ∇5 ∇4
purge ∇9
#4 #5 #4
valve
Fuel ∇4 ∇4 ∇7 ∇3 ∇3 ∇2 ∇2
pressure #5 #4 #6 #3 #3 #2 #2
∇: Warm engine (number inside indicates check order)
#: Cold engine (number inside indicates check order)
ENGINE WARNING LAMP WCH13ASHOOT11017
Among the self-diagnosis items, an engine

warning lamp comes on to notify the driver of
the emission control items when an irregularity
is detected.
Symbol Description
Malfunction indicator lamp
A
(MIL)
ITEMS INDICATED BY THE ENGINE WARNING
LAMP
DOIMH13AR07145
Engine control unit
Front oxygen sensor
Combined map & mat sensor
Crankshaft sensor
Camshaft sensor
Tank purge valve
Throttle body actuator
Detonation/knock sensor
Ignition coil

13A FUEL
Coolant temperature sensor

ENGINE WARNING LAMP INSPECTION
1. Check that when the ignition switch is turned ON, the lamp illuminates.
2. If the lamp does not illuminate, check for open circuit in harness, blown fuse and blown bulb.
3. If the MIL does not illuminate and no “Clicking” sound of power relay is heard, then ECU or power
supply to ECU is faulty. Check power supply to ECU (blown diode, blown fuse, harness) or replace
ECU.
SELF-DIAGNOSIS
The engine control unit monitors the input/output signals (some signals at all times and the others
under specified time or longer) from when the irregular for a specified time or longer from when the
irregular signal is initially monitored, passing a certain number, the engine control unit judges that
an irregularity has occured, memorizes the malfunction code, and outputs the signal to the self-dia-
gnosis output terminal. There are 16 items connector output terminal. There are 16 pins diagnosis
items, and the diagnosis results can be read out with a PADT- II. Moreover, since memorization of the
malfunction codes is backed up directly by the battery, the diagnosis results are memorized even if
the ignition key is turned off. The malfunction code can only be erased turning the ignition switch
to ON and sending the malfunction code erase signal from the PADT- II to the engine control unit.
PADT- II
Diagnosis Chart
NOTE
• Replace the engine control unit if malfunction code is output although the inspection reveals that
there is no problem with the check items.

FUEL 13A
PROBLEM DIAGNOSIS CONTENT CHART- IAFM+/ CFE

TROUBLE DIAGNOS- DIAGNOSTIC DESCRIP-
PADT-II DISPLAY SYMPTOM DESCRIPTION
CODE IS ITEM TION
Front oxygen sensor heater Upstream oxygen sensor
P0030 Open circuit
open circuit heater obdi diagnosis
P0031 Short circuit to gnd
short circuit to ground heater obdi diagnosis
P0032 Short circuit to battery
short circuit to battery heater obdi diagnosis
Upstream oxygen sensor Lambda sensor heater
P0053 Heater fault
heater fault fault
Front oxygen sensor open Upstream oxygen sensor Open circuit / circuit
P0130
circuit signal diagnosis open
Front Oxy- Front oxygen sensor short Upstream oxygen sensor
P0131 Short circuit to ground
gen Sensor circuit to ground signal diagnosis
System Front oxygen sensor short Upstream oxygen sensor
P0132 Short circuit to plus
circuit to battery signal diagnosis
Front oxygen sensor circuit Frequency diagnosis up-
P0133 Frequency too small
slow response stream
Front oxygen sensor not Upstream oxygen sensor Sensor not ready / no
P0134
ready signal diagnosis signal
Front oxygen sensor signal Upstream oxygen sensor Signal excursion not
P0134
excursion not plausible signal diagnosis plausible / signal erra
Oxygen Sensor Signal dur-
Upstream oxygen sensor Signal during fuel cut-
P2297 ing fuel Cut Off not Plaus-
signal diagnosis off not plausible
ible

13A FUEL

CODE IS ITEM TION
Downstream oxygen Downstream oxygen
Rear oxygen sensor heater
P0036 sensor heater obdi dia- sensor heater obdi dia-
open circuit
gnosis gnosis
short circuit to ground
gnosis gnosis
short circuit to battery
gnosis gnosis
Downstream oxygen sensor Lambda sensor heater
P0054 Heater fault
open circuit fault
P0136 Rear Oxy- Rear oxygen sensor open Downstream oxygen

Open circuit
gen Sensor circuit sensor signal diagnosis
System Rear oxygen sensor short Downstream oxygen
circuit to ground sensor signal diagnosis
Rear oxygen sensor short Downstream oxygen
circuit to battery sensor signal diagnosis
Rear oxygen sensor signal Signal plausibility monit- Signal high during fuel
P2A01
high during fuel cut off oring cutoff
Downstream Oxygen
Rear Oxygen Sensor Signal Rear Oxygen Sensor Sig-
P2270 Sensor rich voltage
Stuck Lean nal Stuck Rich
threshold check
Downstream Oxygen
Rear oxygen sensor signal signal high during fuel
P2271 Sensor lean voltage
stuck rich cutoff
threshold check
Enduring camshaft position Enduring camshaft posi- Camshaft position
P0011 deviation at steady set- tion deviation at steady change for diagnosis at
point setpoint steady setpoint
Camshaft sensor not syn-
Cam_in violation of Intake camshaft position
chronise with crankshaft
crk_ref out of range
P0016 reference
Intake camshaft drift from Intake I one-tooth-off Intake camshaft drift of
position diagnosis position
Camshaft Intake camshaft diagnost-
Intake camshaft diagnostic
ic for engine synchroniz- Plausibility
for engine synchronization
P0340 ation
Intake camshaft synchroniz- Intake camshaft synchron- Intake camshaft syn-
ation diagnosis ization diagnosis chronization loss
Intake camshaft signal Intake camshaft signal Intake camshaft signal
P0341
plausibility plausibility implausible
Intake camshaft period dia- Intake camshaft period Intake camshaft period
P0344
gnosis diagnosis out of range

FUEL 13A

CODE IS ITEM TION
AR_RED controller out
of max in PL, Lambda
Fuel System Leak Detected Load/TPS plausibility out of MAX
P0093
– Large Leak check PUT controller out of
max, Lambda out of
MAX,
Fuel System Leak Detected Load/TPS plausibility out of Min
P0094
– Large Leak check
PUT controller out of
max, Lambda out of Min
Intake Air System Restric- Load/TPS plausibility between Min, MAX
P1121
tion check PUT controller out of
max, Lambda between
Min, MAX
Limp-home Adaptation check of TPS limp home limp-home adaptation
P2176
Outside Range position outside range
Throttle position sensor / Load Sensor Failure or
P0068 TPS diagnosis
Throttle body failure Throttle Failure
Throttle Position Sensor
P0101 TPS diagnosis Load Sensor Failure
Throttle failure
P0121 Body Actu- Throttle Position Sensor TPS diagnosis Throttle Failure
ator Diagnostic
Voltage Throttle Position electric position sensor
P0122 position sensor 1 low
Sensor 1 Low diagnosis
P0123 position sensor 1 high
Sensor 1 High diagnosis
Sensor 2 Low diagnosis
Sensor 2 High diagnosis
Throttle Actuator Control-
check of lower return error lower return
ler lower return spring er-
spring of ETC spring check
ror
P1588
Throttle Actuator Control-
check of upper return error upper return
ler upper return spring er-
spring of ETC spring check
ror
Ambient Pressure adapta-
load sensor or throttle
P169F tion error, Throttle Position TPS diagnosis
or AMP failure
Sensor error
Throttle Actuator Control- ETC power stage diagnos-
P2100 open circuit
ler open circuit is
P2101 short circuit
ler short circuit is
P2109

13A FUEL

CODE IS ITEM TION
Throttle Position Sensor check of lower mechanic- lower position not
Lower position not Reached al stop of ETC reached
P2118 over heat protection
ler over heat protection is
ETC position controller PWM exceeds threshold
Throttle Actuator Control- output monitoring 1
ler output position monitor-
ing ETC position controller PWM exceeds threshold
output monitoring 2
P2119
check of lower mechanic- lower mec. stop adapta-
Throttle Actuator Control- al stop of ETC tion outside range
ler Deviation exceed
Threshold ETC control deviation control deviation ex-
diagnosis ceeds threshold
Throttle/Pedal Ratio
Ratio check
check
TPS – MAF plausibility
Throttle/Pedal Position TPS1 plaus error
P2135 check
plausibility
TPS – MAF plausibility
TPS2 plaus error
check
TPS rationality check TPS ratio error
Throttle Position Sensor check of upper mechanic- upper position not
P2163
Upper Position not Reached al stop of ETC reached
check of adaptation con- adaptation conditions
P2176 Adaptation Exceed
dition exceeded
Threshold
of min in PL, Lambda
between Min, MAX
P2279 Intake Air System Leak
min, Lambda between
Min, MAX
Air Flow Restriction/Air AR_RED controller out
Leak Between Air Filter and of max in PL, Lambda
MAF controller not enable
P2280
Air Flow Restriction/Air PUT controller out of
Leak Between Air Filter and max, Lambda controller
MAF Load/TPS plausibility not enable
check
Air Leak Between MAF and
Throttle Body
out of Max
Throttle Body
P2281 out of Min
min, Lambda out of
Throttle Body
MAX
Air Leak Between MAF and PUT controller out of
Throttle Body min, Lambda out of Min

FUEL 13A

CODE IS ITEM TION
Air Leak Between Throttle controller not enable
P2282
Body and Intake Valves PUT controller out of
min, Lambda controller
not enable
Ambient pressure plausibil- Ambient pressure plaus- Ambient pressure not
P0102
ity ibility plausible
Manifold air pressure
Manifold air pressure Signal line short to
P0103 sensor short circuit to
sensor diagnosis ground
ground
Manifold air pressure
Manifold air pressure Signal line short to bat-
P0106 sensor short circuit to bat-
sensor diagnosis tery voltage
tery
TMap
Manifold absolute pressure Manifold pressure plaus- Manifold pressure not
P0111 Sensor
not plausible (MAP) ibility plausible
Intake Air Temperature
P0112 TIA stuck signal diagnosis Stuck TIA signal
Sensor plausibility
Intake Air Temperature
TIA signal electrical dia- Signal short circuit to
P0113 Sensor 1 short Circuit to
gnosis ground
ground
Intake Air Temperature TIA signal electrical dia-
P2227 Signal open circuit
Sensor 1 open Circuit gnosis
Coolant temperature sensor Coolant temperature
Coolant short circuit to ground signal range diagnosis
Temperat- Coolant temperature sensor Coolant temperature Short circuit to vbatt or
P0118
ure Sensor open circuit signal range diagnosis open circuit
System Coolant temperature signal Coolant temperature Coolant temperature
P0119
gradient error signal range diagnosis signal gradient error
P0122 Pedal voltage sensor 1 low Pvs_1 out of range check Pedal Voltage 1 low
P0123 Accelerat- Pedal voltage sensor 1 high Pvs_1 out of range check Pedal Voltage 1 high
or Pedal
P0222 Sensor Pedal voltage sensor 2 low Pvs_2 out of range check Pedal Voltage 2 low
P0223 Pedal voltage sensor 2 high Pvs_2 out of range check Pedal Voltage 2 high
Fuel system diagnosis for Maximum limit of
Maximum limit of Lambda
lambda controller monit- lambda controller is
controller is reached
oring reached
P0171
Fuel system diagnosis for
Maximum limit of adapta- Maximum limit of adapt-
lambda adaptation mon-
tion value was reached ation value was reached
Oxygen itoring
Control Fuel system diagnosis for Minimum limit of
Minimum limit of Lambda
lambda controller monit- lambda controller is
controller is reached
oring reached
P0172
Fuel system diagnosis for
Minimum limit of adapta- Minimum limit of adapt-
lambda adaptation mon-
tion value was reached ation value was reached
itoring

13A FUEL

CODE IS ITEM TION
Injector Circuit/Open – Cyl- Injection valve diagnostic
P0201 Cylinder 1 open circuit
inder 1 - open circuit
Cylinder 1 Injector short Injection valve diagnostic Cylinder 1 short circuit
P0261
circuit to ground - short circuit ground ground
P0262
Injector circuit to battery - short circuit plus plus
System Cylinder 2 Injector short Injection valve diagnostic Cylinder 2 short circuit
P0264
P0265
circuit to battery - short circuit plus plus
P0267
P0268
P0270
P0271
Fuel Pump Relay Open Cir- Fuel pump electrical dia-
P025A Open circuit
cuit gnostic
Fuel Pump Fuel Pump Relay Short Cir- Fuel pump electrical dia-
P025C Short circuit to ground
Relay cuit to Ground gnostic
Fuel Pump Relay Short Cir- Fuel pump electrical dia-
P025D Short circuit to battery
cuit to Battery gnostic
Random/multiple cylinder Random or multiple mis-
P0300 Plausibility
misfire detected fire diagnosis
P0301 Cylinder 1 misfire detected Misfire diagnosis Misfire on cylinder 1
Misfire
Knock acquisition chain
P0324 Knock control system error Knck spi failure
diagnosis
Knock
Basis knock signal dia-
P0325 Sensor Sys- Knock sensor error Knck sensor basic failure
gnosis
tem
Relative knock signal dia- Relative knock signal Knck sensor relative fail-
P0326
gnosis diagnosis ure

FUEL 13A

CODE IS ITEM TION
Crankshaft sensor failure Crankshaft sensor failure Crankshaft sensor failure
P0335 open or short circuit dia- open or short circuit dia- open or short crk_oc cir-
gnosis gnosis cuit
Crankshaft signal miss-
Crankshaft signal missing Crankshaft signal missing
ing
Crankshaft signal implaus- Crankshaft signal im- Crankshaft signal im-
Crankshaft ible plausible plausible
Sensor
Crankshaft loss of synchron- Crankshaft loss of syn- Crankshaft synchroniza-
P0336
ization diagnosis chronization diagnosis tion lost
Crankshaft tooth number Crankshaft tooth number Wrong crankshaft tooth
error diagnosis error diagnosis number
Crankshaft tooth period Crankshaft tooth period Crankshaft tooth period
diagnosis diagnosis out of range
P0351 Ignition Coil 1 open circuit
Open circuit
Ignition Coil 1 short circuit
to ground
to battery
P2303 Ignition Ignition Coil 3 short circuit Short circuit to ground

Coil Sys- to ground Ignition Diagnosis
tem Ignition Coil 3 short circuit
to battery
to ground
to battery
to ground
to battery
Catalyst Catalyst system efficiency Catalyst efficiency dia-
P0420 Catalyst efficiency
Converter below threshold gnosis
Canister purge solenoid Cannister purge Solenoid Present electrical cps
P0444
valve Open Circuit diagnostic oc failure open circuit
Cannister Canister Purge Solenoid Present electrical cps
Cannister purge Solenoid
P0458 purge Diagnostic Short Circuit to failure short circuit to
diagnostic scg
Solenoid Ground ground
Valve Canister Purge Solenoid Present electrical cps
Cannister purge Solenoid
P0459 Diagnostic Short Circuit to failure short circuit to
diagnostic scp
Battery battery

13A FUEL

CODE IS ITEM TION
P0480 Fan 1 Open circuit Open circuit Fan 1 Open circuit
Fan 1 Short circuit To Fan 1 Short circuit To
Engine fan ground ground
Fan 1 Short circuit To Bat- Fan 1 Short circuit To
P0692 Short circuit to battery
tery Battery
Electrical diagnosis of vs
P0500 Vehicle Vehicle speed sensor Vs sensor defective
sensor
speed
sensor Vehicle speed correlation Electrical diagnosis of vs
P215A Vs can not valid
not valid can
Brake light BLS-BTS check detected
P0504 Brake Switch Error Plausibility
switch error
Engine speed at idle is be-
Index for diagnostic isc
P0506 low calculated idle speed Present isc_low failure
Engine too low
target
speed
sensor Engine speed at idle is
Index for diagnostic isc
P0507 above calculated idle speed Present isc_high failure
too high
target
immobilizer failure due
P0513 Immobilizer locked to wrong authentication Wrong transponder
Immob- process
ilzer immobilizer failure due
Communication with
P0633 to no communication Transponder missing
transponder missing
with transponder
P0562 Battery voltage too low Battery voltage too low Battery voltage too low
P0563 Power Battery voltage too high Battery voltage too high Battery voltage too high
Supply Battery voltage too high Battery voltage too high Battery voltage too high
P1793
Battery voltage too low Battery voltage too low Battery voltage too low
ECU Warm-reset diagnos- ECU Warm-reset diagnos-
P0604 ECU Warm Reset
is is
P0606 ECU Internal Fault SPI Bus communication ECU Monitoring
P060A ECU Internal Fault - General General monitoring General monitoring
ECU Internal Fault - Pro- Processor monitoring
P060C ECU Monitoring
cessor monitoring failure
ECU
Actual or requested
Torque intervention for Torque intervention for
P061A torque higher than al-
safety active satety active
lowed limit
P061B Torque monitoring Torque monitoring Torque monitoring
Internal Control Module
P061C N_LIM monitoring ECU internal Monitoring
Engine RPM Performance
P0615 Starter relay open circuit Starter relay Open circuit
Starter relay short circuit to
P0616 Starter Starter relay Short circuit to ground
ground
Control
Starter relay short circuit to
P0617 Starter relay Short circuit to battery
battery

FUEL 13A

CODE IS ITEM TION
Sensor Reference Voltage
P0642 Vcc low diagnostic Supply Voltage low
“A” Circuit Low
P0643 Vcc high diagnostic Supply Voltage high
Supply “A” Circuit High
Voltage Sensor Reference Voltage
P0652 Vcc low diagnostic Supply Voltage low
“B” Circuit Low
P0653 Vcc high diagnostic Supply Voltage high
“B” Circuit High
Air condition clutch, open
P0645 Open circuit
circuit
Air cond Air condition clutch, short Air conditioning com-
clutch circuit to ground pressor diagnosis
Air condition clutch, short
circuit to battery
VIM Actuator Electrical VIM Actuator open cir-
P0660 kiv
Power Stage Diagnosis cuit
VIM Actu- VIM Actuator Electrical VIM Actuator short cir-
P0661 kiv
ator Power Stage Diagnosis cuit to ground
VIM Actuator Electrical VIM Actuator short cir-
P0662 kiv
Power Stage Diagnosis cuit to plus
Main relay input Open Cir- Main relay input OL Main relay input Open
P0685
cuit electrical diagnosis Circuit
Main relay input Short cir- Main relay input SCG Main relay input Short
P0686
cuit to Ground electrical diagnosis circuit to Ground
Main relay input Short cir- Main relay input SCP Main relay input Short
P0687
cuit to Battery electrical diagnosis circuit to Battery
Main relay
Main relay ON output dia- Main relay ON output Main relay ON output
P0689
gnosis plausibility diagnosis plausibility diagnosis plausibility
Main relay OFF output dia- Main relay OFF output Main relay OFF output
P0690
gnosis plausibility diagnosis plausibility diagnosis plausibility
Main relay switch ON too Main relay switch ON too Main relay switch ON
P2510
slow slow too slow
Transmission control unit Transmission control unit
P0700 Tcu Transmission Limp Home
limphome diagnosis limphome diagnosis
Hardwired p/n switch
P0850 P/n switch P/n switch plausibility Plausabile value
diagnosis
Pedal / Brake Pedal Position/Accel-
P2299 Brake erator Pedal Position Incom- Plausibilty brake error Plausibility
Switch patible

13A FUEL

CODE IS ITEM TION
U0073 Can diagnosis - buss off Can diagnosis Can bus off
Error in the respective
Can diagnosis - lost commu- control unit (cu) commu-
U0100 Can diagnosis for ecu
nication with ecu nicating on the can-hs
bus
U0101 Can diagnosis for tcu
Can com- nication with tcu nicating on the can-hs
munica- bus
tion Error in the respective
U0121 Can diagnosis for abs
nication with abs/esp nicating on the can-hs
bus
U0140 Can diagnosis for icu
nication with meter cluster nicating on the can-hs
bus
INSPECTION CHART FOR DIAGNOSIS CODES WCH13ASHOOT11018
FAULT CODE Diagnosis items Reference page

P0011
P0016
P0340 Camshaft Sensor 13A/29
P0341
P0344
P0030
P0031
P0032
P0130
P0131
Front Oxygen Sensor System 13A/31
P0132
P0133
P0134
P0053
P2297

FUEL 13A

P0036
P0037
P0038
P0136
P0137
Rear Oxygen Sensor System 13A/34
P0138
P2A01
P0054
P2270
P2271
P0093
P0094
P0068
P1121
P2176
P0101
P0121
P0122
P0123
P0222
P0223
P1588
P169F Throttle Body Actuator System 13A/37
P2100
P2101
P2109
P2118
P2119
P2135
P2163
P2176
P2279
P2280
P2281
P2282
P0102
P0103
P0106
P0111 TMap Sensor 13A/42
P0112
P0113
P2227

13A FUEL

P0117
P0118 Coolant Temperature Sensor System 13A/46
P0119
P0122
P0123
Accelerator Pedal Sensor 13A/49
P0222
P0223
P0171
Oxygen Control 13A/51
P0172
P0201
P0202
P0203
P0204
P0261
P0262
Injectors System 13A/54
P0264
P0265
P0267
P0268
P0270
P0271
P025A
P025C Fuel Pump Relay 13A/57
P025D
P0300
P0301
P0302 Misfire 13A/59
P0303
P0304
P0324
P0325 Knock Sensor System 13A/62
P0326
P0335
Crankshaft Sensor 13A/65
P0336

FUEL 13A

P0351
P0352
P0353
P0354
P2300
P2301
Ignition Coil System 13A/67
P2303
P2304
P2306
P2307
P2309
P2310
P0420 Catalytic Converter 13A/69
P0444
P0458 Cannister Purge Solenoid Valve 13A/71
P0459
P0480
P0691 Engine Fan 13A/74
P0692
P0500
Vehicle Speed Signal (A/T) 13A/76
P215A
P0500
Vehicle Speed Signal (M/T) 13A/79
P215A
P0504 Brake Light Switch 13A/82
P0506
Engine Speed Signal (A/T) 13A/84
P0507
P0506
Engine Speed Signal (M/T) 13A/87
P0507
P0513
Immobilizer 13A/90
P0633
P0562
P0563 Power Engine Control Unit 13A/92
P1793
P0604
P0606
P060A
P060C Engine Control Unit 13A/94
P061A
P061B
P061C

13A FUEL

P0615
P0616 Starter Control 13A/96
P0617
P0642
P0643
Sensor Supply 13A/98
P0652
P0653
P0645
P0646 Compressure 13A/101
P0647
P0660
P0661 Vacuum Actuator 13A/104
P0662
P0685
P0686
P0687
Main Relay 13A/106
P0689
P0690
P2510
P0700 Automatic Transmission Control Unit 13A/109
P0850 P / N Switch 13A/111
P2299 Pedal / Brake Switch 13A/113
U0073
U0100
U0101 CAN Interface 13A/116
U0121
U0140

FUEL 13A
INSPECTION PROCEDURE FOR DIAGNOSIS CODES / 29
INSPECTION PROCEDURE FOR DIAGNOSIS CODES WCH13ASHOOT11008
CAMSHAFT SENSOR
DOIMC13AR11006
OPERATION
The camshaft sensor detects the top dead centre on the compression stroke of the No. 1 cylinder,
converts it into a pulse signal and inputs it to the engine control unit. The engine control unit determ-
ines the fuel injection sequence based on this signal.
Power to the top camshaft is supplied from the ignition switch (IG) and is earthed to the engine control
unit. The camshaft sensor generates a pulse signal as it repeatedly connects and disconnects between
5V voltage supplied from the engine control unit and earth.

13A FUEL
/ 30 INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Check condi-
Fault codes PADT-II Display Symptom description Range of Check
tion
Enduring camshaft posi- Camshaft position
Engine is run-
P0011 tion deviation at steady change for diagnosis
ning
setpoint at steady setpoint
Camshaft sensor not
intake camshaft posi- • Engine is run-
synchronise with Crank- Ignition switch: ON
tion out of range • ning
P0016 shaft reference Engine speed is ap-
Intake Camshaft Drift intake camshaft drift prox. 500 r/min or Engine is run-
from Position of position more. ning
Set conditions:
intake camshaft dia-
• Sensor output Engine is run-
gnostic for engine syn- Plausibility
voltage does not ning
P0340 chronization
change for 4
intake camshaft syn- intake camshaft syn- seconds (no pulse Engine is run-
chronization diagnosis chronization loss signal input) ning
intake camshaft signal intake camshaft signal Engine is run-
P0341
plausibility implausible ning
intake camshaft period intake camshaft period Engine is run-
P0344
diagnosis out of range ning
TROUBLESHOOTING PROCEDURE
DOIMC13AR11044

FUEL 13A
TROUBLESHOOTING OF FRONT OXYGEN SENSOR WCH13ASHOOT11001
DOIMC13AR11001
OPERATION
The oxygen sensor function is to detect the concentration of oxygen in the exhaust gas; it converts
those data to voltage, and inputs the resulting signals to the engine control unit.
If the air and fuel mixture ratio is richer than the theoretical air and fuel mixture ratio (i.e., if the
concentration of oxygen in the exhaust gas is sparse), a voltage of approximately 1V is output; if the
air and fuel mixture ratio is leaner than the theoretical air and fuel mixture ratio (i.e., if the concen-
tration is dense), a voltage of approximately 0V is output.
Battery power supply is applied, by way of the control relay, to the oxygen sensor heater. As a result,
the sensor element is heated by the heater, so that the oxygen sensor shows excellent response even
if the temperature of the exhaust gas is low.

13A FUEL
Fault
PADT-II Display Symptom description Range of Check Check condition
Codes
Front oxygen sensor heat- • 3 minutes have
P0030 Open circuit Engine is running
er open circuit passed after
Front oxygen sensor heat- engine was
P0031 Short circuit to GND started. Engine is running
er short circuit to ground
• Engine coolant
Front oxygen sensor heat- Short circuit to bat-
P0032 temperature is Engine is running
er short circuit to battery tery
approx. 80 °C
Front Oxygen Sensor Open Open circuit / Circuit (176 °F) or
P0130 Engine is running
Circuit Open more.
Front Oxygen Sensor Short Short circuit to • Intake air tem-
Circuit to Ground ground perature is 20 -
Front Oxygen Sensor Short 50 °C (68 -122
P0132 Short circuit to plus °F) Engine is running
Circuit to Battery
• Engine speed is
Front oxygen Sensor Cir-
P0133 Frequency too small approx. 2000 - Engine is running
cuit Slow Response
3000 r/min
Front Oxygen Sensor not Sensor not ready / • Vehicle is mov- Engine is running
Ready No signal ing at constant
P0134 Signal excursion not speed on a
Front Oxygen Sensor Sig-
plausible / Signal er- flat, level road Engine is running
nal Excursion Not Plausible
ror surface .
Upstream Oxygen Sensor Lambda sensor Heat- Set conditions
P0053 :- Engine is running
Heater Fault er fault
• The oxygen
sensor (front)
output voltage
around 0.6 V
for 30 seconds
(does not cross
0.6 V for 30
seconds).
• When the
range of check
Oxygen Sensor Signal dur- operations giv-
Signal during fuel
P2297 ing fuel Cut Off not Plaus- en above Engine is running
cut-off not plausible
ible which accom-
pany start of
the engine are
carried out
four time in
succession, a
problem is de-
tected after
each opera-
tion.
Function PADT-II Display Check Condition Standard Value
Dynamic Front Oxygen Sensor Ignition On ± 405.18 mv
Display Voltage Engine runs at idle 180 ~ 400

FUEL 13A

Actuator Front Oxygen Sensor Front Oxygen controller =
Idle speed
Test Heater ON
DOIMC13AR11037

13A FUEL
TROUBLESHOOTING OF REAR OXYGEN SENSOR WCH13ASHOOT11007
DOIMC13AR11030
OPERATION

FUEL 13A
The oxygen sensor function is to detect the concentration of oxygen in the exhaust gas; it converts
those data to voltage, and inputs the resulting signals to the engine control unit.
Battery power supply is applied, by way of the control relay, to the oxygen sensor heater. As a result,
the sensor element is heated by the heater, so that the oxygen sensor shows excellent response even
if the temperature of the exhaust gas is low.
Fault Symptom descrip-

PADT-II Display Range of Check Check condition
Codes tion
Downstream oxygen • 3 minutes have
Rear oxygen sensor heat-
P0036 sensor heater OBDI passed after en- Engine is running
er open circuit
diagnosis gine was started.
Downstream oxygen • Engine coolant
Rear oxygen sensor heat- temperature is
P0037 sensor heater OBDI Engine is running
er short circuit to ground approx. 80 °C
diagnosis
(176 °F) or more.
Downstream oxygen
Rear oxygen sensor heat- • Idle position
P0038 sensor heater OBDI Engine is running
er short circuit to battery switch:OFF
diagnosis
• The throttle posi-
Rear Oxygen Sensor Open tion sensor out-
P0136 Open circuit Engine is running
Circuit put voltage is4.1
Rear Oxygen Sensor Short Short circuit to V or more.
Circuit to Ground ground • Open loop con-
Rear Oxygen Sensor Short trol in operation.
P0138 Short circuit to plus • 20 seconds have Engine is running
Circuit to Battery
Rear Oxygen Sensor passed after de-
P0139 Diag inhibited. celeration fin- Engine is running
Rich/Lean Switching Time
ished.
Downstream Oxygen Lambda sensor Heat- Set conditions :-
Sensor Open Circuit er fault • The oxygen
Downstream Oxygen sensor (rear) out-
Rear Oxygen Sensor Sig-
P2270 Sensor rich voltage put voltage is 0.1 Engine is running
nal Stuck Lean
threshold check V or less.
Downstream Oxygen • The difference in
Rear Oxygen Sensor Sig- the maximum
P2271 Sensor lean voltage Engine is running
nal Stuck Rich and minimum
threshold check
values for the
oxygen sensor
(rear) output
voltage is 0.08 V
or less.
• The oxygen
Rear oxygen sensor signal Signal high during sensor (rear) out-
P2A01 put voltage is 0.5 Engine is running
high during fuel cut off fuel cut off
V or more.
• The above condi-
tions continue
for a continuous
period of 5
seconds.

13A FUEL

Dynamic Dis- Ignition On ± 49974.7 mv
Rear Oxygen Sensor Voltage
play Engine runs at idle 180 ~ 401
Rear Oxygen controller
Actuator Test Rear Oxygen Sensor Heater Idling speed
= ON
DOIMC13AR11043

FUEL 13A
THROTTLE BODY ACTUATOR WCH13ASHOOT11003
DOIMC13AR11003
OPERATION
The throttle body actuator converts the throttle position opening into a voltage signal and inputs it
into the engine control unit, which controls the fuel injection, based on the input signal.
The 5V power in the engine control unit is supplied to the throttle position sensor. It flows through
the resistor in the sensor and is earthed in the engine control unit.
As the throttle valve shaft rotates to wide open position, the resistance between the variable resistor
terminal of the throttle position sensor and the earth terminal increases. As a result, the voltage across
the throttle position sensor variable resistance terminal also increases.

13A FUEL
Check condi-
Fault codes PADT-II Display Symptom Description Range of Check
tion
Throttle position sensor Load Sensor Failure or Engine is run-
P0068
/ Throttle body failure Throttle Failure ning
Engine is run-
ning
Fuel System Leak Detec- out of MAX
P0093
ted – Large Leak PUT controller out of
Engine is run-
max, Lambda out of
ning
MAX,
Engine is run-
ning
Fuel System Leak Detec- out of Min
P0094
ted – Large Leak PUT controller out of
Engine is run-
max, Lambda out of
ning
Min
Throttle Position Sensor Engine is run-
P0101 Load Sensor Failure
failure ning
Throttle Position Sensor • Ignition switch: ON Engine is run-
P0121 Throttle Failure • Excluding 60
Diagnostic ning
seconds after the
Voltage Throttle Posi- Engine is run-
P0122 position sensor 1 low ignition switch is
tion Sensor 1 Low ning
turned to ON or
Voltage Throttle Posi- immediately after Engine is run-
tion Sensor 1 High the engine starts. ning
Voltage Throttle Posi- Set conditions: Engine is run-
tion Sensor 2 Low • When the idle ning
Voltage Throttle Posi- switch out is ON, Engine is run-
P0223 position sensor 2 high sensor output
tion Sensor 2 High ning
voltage is 2 V or
more for 4 Engine is run-
seconds. ning
Intake Air System Restric- between Min, MAX • Sensor output
P1121
tion PUT controller out of voltage is 0.2 V or Engine is run-
max, Lambda between less for 4 seconds. ning
Min, MAX
Throttle Actuator Con-
error lower return Engine is run-
troller lower return
spring check ning
spring error
P1588
error upper return Engine is run-
troller upper return
spring check ning
spring error
Throttle Actuator Con- Engine is run-
P2100 open circuit
troller open circuit ning
Throttle Actuator Con- Engine is run-
P2101 short circuit
troller short circuit ning
lower position not Engine is run-
P2109 Lower position not
reached ning
Reached
Engine is run-
P2118 over heat protection
ning

FUEL 13A
Check condi-
tion
troller over heat protec-
tion
PWM exceeds Engine is run-
Throttle Actuator Con- threshold 1 ning
troller output position
monitoring PWM exceeds Engine is run-
threshold 2 ning
P2119
lower mec. stop adapt- Engine is run-
Throttle Actuator Con- ation outside range ning
troller Deviation exceed
Threshold control deviation ex- Engine is run-
ceeds threshold ning
Throttle/Pedal Ratio Engine is run-
check ning
Engine is run-
TPS1 plaus error
Throttle/Pedal Position ning
P2135
plausibility Engine is run-
TPS2 plaus error
ning
Engine is run-
TPS ratio error
ning
upper position not Engine is run-
P2163 Upper Position not
reached ning
Reached
adaptation conditions Engine is run-
P2176 Adaptation Exceed
exceeded ning
Threshold
Engine is run-
ning
between Min, MAX
P2279 Intake Air System Leak
Engine is run-
min, Lambda between
ning
Min, MAX
Air Flow Restriction/Air AR_RED controller out
Engine is run-
Leak Between Air Filter of max in PL, Lambda
ning
and MAF controller not enable
P2280
Air Flow Restriction/Air PUT controller out of
Engine is run-
Leak Between Air Filter max, Lambda control-
ning
and MAF ler not enable
Air Leak Between MAF Engine is run-
and Throttle Body ning
out of Max
P2281 of min in PL, Lambda
out of Min
min, Lambda out of
MAX

13A FUEL
Check condi-
tion
min, Lambda out of
Min
Engine is run-
Air Leak Between ning
controller not enable
P2282 Throttle Body and In-
take Valves PUT controller out of
Engine is run-
min, Lambda control-
ning
ler not enable
Ambient Pressure adapt-
load sensor or throttle Engine is run-
P169F ation error, Throttle Pos-
or AMP failure ning
ition Sensor error
Check condi-
Function PADT-II Display Full name Standard value
tion
Throttle Posi-
Throttle posi-
tion Signal Idle speed 5.49 %
tion signal
(TPS)
Throttle body
TBA Adapta-
actuator adap- Idle speed Done
tion
tion
Throttle body
DK Output
actuator out- Idle speed Performed
Stage
put stage
Emergency
Emergency TBA
Dynamic Display Adaptation throttle body
Idle speed OFF
actuator adapt-
Value
ation value
Sleep Mode Sleep mode
Idle speed OFF
Active active
IPA Active Test IPA active test Idle speed Performed
LIMP Home LIMP home fuel
Idle speed OFF
Fuel Cut cut
TBA cancelled
TBA — Act Out
— actuation Idle speed Performed
Of Range
out of range
Function PADT-II Display Check condition Standard value
Throttle Value Engine is running 1.00000
1. RPM goes 1500 rpm
Actuator Test
Throttle Body Shut-off Engine is running 2. Condensor fan OFF
3. Radiator fan OFF

FUEL 13A
DOIMC13AR11039

13A FUEL
TMAP SENSOR (INTAKE AIR TEMPERATURE SENSOR AND VACUUM SENSOR)

WCH13ASHOOT11002
DOIMC13AR11002
OPERATION INTAKE AIR TEMPERATURE SENSOR

The intake air temperature sensor, which is integrated with the Tmap sensor converts the engine intake
air temperature into a voltage and inputs it to the engine control unit, which then corrects the fuel
injection rate, etc., based on input signal.
The 5 power in the engine control unit is supplied via a resistor in the unit to the intake air temperature
sensor. Via the sensor which is a kind of resistor, it is then earthed in the engine control unit. The intake
air temperature sensor resistor has such characteristic that its resistance decreases as the intake air
temperature rises.
The intake air temperature sensor terminal voltage increases or decreases. Therefore, the intake air
temperature sensor terminal voltage changes with the intake air temperature, decreasing as the
temperature rises.

FUEL 13A
OPERATION FOR VACUUM SENSOR

The vacuum sensor which is integrated in the Tmap sensor converts the air intake plenum pressure
to a voltage value and inputs it to the engine control unit. The engine control unit uses this signal
and the engine rpm to calculate the basic fuel injection timing.
5V of power is supplied to the vacuum sensor from the engine control unit, and the sensor circuit
earth is located in the engine control unit. The vacuum sensor output voltage is proportioned to the
air intake plenum pressure and sent to the engine control unit.
Check condi-
Fault codes PADT-II Display PADT-II Display Range of Check
tion
Manifold air pressure • Ignition switch: ON
Signal line short to Engine is run-
P0102 sensor short circuit to • The output voltage
ground ning
ground of the boost sensor
Manifold air pressure is 4.5 V or more
Signal line short to for 4 seconds. (This Engine is run-
P0103 sensor short circuit to
battery voltage corresponds to the ning
battery
absolute manifold
pressure of 100
kPa (14.23 psi,
30.19 in.Hg) or
more).
• The output voltage
of the throttle
sensor is 1.25 V or
more.
• The vehicle is sta-
Manifold absolute pres- Manifold pressure not tionary Engine is run-
P0106
sure not plausible (MAP) plausible Set conditions: ning
• The output voltage
of the boost sensor
is 0.2 V or less for
4 seconds. (This
correspond to the
absolute manifold
pressure of 4.9
kPa (0.7 psi, 1.48
in.Hg) or less).

13A FUEL
Check condi-
Fault codes PADT-II Display PADT-II Display Range of Check
tion
Intake Air Temperature • Ignition switch: ON Engine is run-
P0111 Stuck TIA signal
Sensor plausibility • Excluding 60 ning
Intake Air Temperature seconds after the
Signal short circuit to ignition switch is Engine is run-
P0112 Sensor 1 short Circuit to
ground turned to ON or ning
ground
immediately after
Intake Air Temperature Engine is run-
P0113 Signal open circuit the engine starts.
Sensor 1 open Circuit ning
Set conditions:
• Sensor output
voltage is 4.6 V or
more (correspond-
ing to an intake air
temperature of
-45 °C (-49 °F) or
Ambient pressure plaus- Ambient pressure not less) for 4 seconds. Engine is run-
P2227 • Sensor output
ibility plausible ning
voltage is 0.2 V or
less (corresponding
to an intake air
temperature of
125 °C (257 °F) or
more) for 4
seconds.
Intake Air Temper- 33 °C (91.4 °F) ( 0 °C (32 °F) ~ 100 °C (212
Ign on
ature °F))
Dynamic Display Ign on 1010 Hpa
Intake manifold
pressure Engine runs at
410 Hpa
idle

FUEL 13A
DOIMC13AR11038

13A FUEL
COOLANT TEMPERATURE SENSOR WCH13ASHOOT11004
DOIMC13AR11004
OPERATION
The coolant temperature sensor converts the coolant temperature into a voltage and inputs it to the
engine control unit, which then control fuel injection rate and fast idle speed when the engine is cold,
based on the input signal.
The 5V power in the engine control unit is supplied via a resistor in the unit to the coolant temperature
sensor. Via the sensor which is a kind of resistor, it is then earthed in the engine control unit. The
coolant temperature sensor resistor has such characteristic that its resistance decreases as the coolant
temperature rises.
The coolant temperature sensor terminal voltage increases or decreases. Therefore, the coolant tem-
perature sensor terminal voltage changes with the coolant temperature, decreasing as the temperature
rises.

FUEL 13A
Check condi-
tion
Coolant Temperature • Ignition switch: ON
Short circuit to Engine is run-
P0117 Sensor Short Circuit to • Excluding 60
ground ning
Ground seconds after the
Coolant Temperature Short circuit to Vbatt ignition switch is Engine is run-
P0118 turned to ON or
Sensor Open Circuit or Open circuit ning
immediately after
the engine starts.
Set conditions:
• Sensor output
voltage is 4.6 V or
more (correspond-
ing to an engine
coolant temperat-
ure of -45 °C (-49
°F) or less) for 4
seconds.
• Sensor output
voltage is 0.1 V or
less for (corres-
ponding to an en-
gine coolant tem-
perature of 140 °C
(284 °F) or more)
for 4 seconds.
• Ignition switch: ON
Coolant Temperature Coolant temperature • Engine speed is ap- Engine is run-
P0119 prox. 500 r/min or
Signal Gradient Error signal gradient error ning
more.
Set conditions:
• The sensor output
voltage increases
from 1.6 V or less
(corresponding to
an engine coolant
temperature of 40
°C (104 °F) or
more) to 1.6 V or
more (correspond-
ing to an engine
coolant temperat-
ure of 40 °C (104
°F) or less)
• After this, the
sensor output
voltage is 1.6 V or
more for 5
minutes.

13A FUEL

Engine temperature Engine runs at idle 89 °C (192.2 °F)
Dynamic Display Engine start temperat- 29 °C (84.2 °F) ( 0 °C (32 °F) ~
Engine runs at idle
ure 100 °C (212 °F))
DOIMC13AR11040

FUEL 13A
ACCELERATOR PEDAL SENSOR WCH13ASHOOT11013
DOIMC13AR11014
OPERATION
The accelerator pedal sensor converts the changes (increase or decrease) of the depressed pedal into
pulse signal and inputs these signals to the engine control unit. The engine conrol unit determines
how much the changes of the depressed pedal.
5V power is supplied to the accelerator pedal sensor from the engine control unit, and the earth
connection is positioned to engine control unit.

13A FUEL

codes tion
Pedal voltage • Set the condi-
P0122 Pedal Voltage 1 low Engine is running
sensor 1 low tion: Engine
Pedal voltage stopped, ignition
P0123 Pedal Voltage 1 high on. Engine is running
sensor 1 high
• Carry out test
Pedal voltage
P0222 Pedal Voltage 2 low when no-load Engine is running
sensor 2 low
applied on accel-
erator pedal:
1. Measure the
pedal posi-
tion angle:
approxim-
ately 75.
2. Accelerator
pedal posi-
tion: ON as
displayed in
dynamics dis-
play.
Pedal voltage • Carry out test
P0223 Pedal Voltage 2 high when accelerator Engine is running
sensor 2 high
pedal is de-
pressed:
1. Measure the
pedal posi-
tion angle:
approxim-
ately 88.
2. Accelerator
pedal posi-
tion: ON as
displayed in
dynamics dis-
play.
0.00%
Accelerator Pedal
Dynamic Display Ignition On (Varies as APS pedal is
Position
pressed)

FUEL 13A
DOIMC13AR11049
OXYGEN CONTROL WCH13ASHOOT11085
DOIMC13AR07132
OPERATION
The oxygen control which is integrated with oxygen sensor, works by detecting the concentration of
oxygen in exhaust gas; it converts those data to voltage, and inputs the resulting signals to the engine
control unit.

13A FUEL
Fault codes PADT-II Display Symptom description Check condition

Maximum limit of lambda con- Maximum limit of lambda
Engine is running
troller is reached controller is reached
0171
Maximum limit of adaptation Maximum limit of adaptation
Engine is running
value was reached value was reached
Minimum limit of lambda con- Minimum limit of lambda
Engine is running
troller is reached controller is reached
0172
Minimum limit of adaptation Minimum limit of adaptation
Engine is running
value was reached value was reached
Function PADT-II Display Check condition Standard Value
Ignition On 1
Oxygen control factor
Engine runs at idle 0.99 ~1.01
Oxygen long term adapta-
tion
Dynamic Display
Engine runs at idle ± 30
tion multiplicative value
tion fuel mass flow offset

FUEL 13A
DOIMC13AR11036

13A FUEL
INJECTORS WCH13ASHOOT11012
DOIMC13AR11009
OPERATION

FUEL 13A
The injector is an injection nozzle with a solenoid valve which injects fuel according to the injection
signal coming from the engine control unit.
The injector has a fixed nozzle opening area and the fuel pressure against manifold inside pressure
is regulated to a fixed level. Therefore, the volume of fuel injected by the injector is determined by
the time during which needle valve is open, namely, by the time during which the solenoid coil is
energized.
The battery voltage is applied through the main relay to this injector. When the engine control unit
turns ON the power transistor integrated inside it, the solenoid coil is energized to open the injector
valve, which then injects fuel.
Fault
PADT-II Display Symptom description Range of Check Check Condition
Code
Injector Cir-
Injection valve dia-
P0201 cuit/Open – Cylinder Engine is running
gnostic - open circuit
1
Injector Cir-
2
Injector Cir-
3
Injector Cir-
4 • Engine speed is ap-
Cylinder 1 Injector Injection valve dia- prox. 500-1000
P0261 short circuit to gnostic - short circuit r/min Engine is running
ground ground • The throttle posi-
Cylinder 1 Injector Injection valve dia- tion sensor output
P0262 short circuit to bat- gnostic - short circuit voltage is 1.15 V or Engine is running
tery plus less
• Actuator test by
Cylinder 2 Injector Injection valve dia- PDT-2000 is not
P0264 short circuit to gnostic - short circuit carried out. Engine is running
ground ground Set conditions:-
Cylinder 2 Injector Injection valve dia- • Surge voltage of
P0265 short circuit to bat- gnostic - short circuit injector coil is not Engine is running
tery plus detected for 4
Cylinder 3 Injector Injection valve dia- seconds.
P0267 short circuit to gnostic - short circuit Engine is running
ground ground
Cylinder 3 Injector Injection valve dia-
P0268 short circuit to bat- gnostic - short circuit Engine is running
tery plus
P0270 short circuit to gnostic - short circuit Engine is running
ground ground
P0271 short circuit to bat- gnostic - short circuit Engine is running
tery plus

13A FUEL

Ign on 0 MS
Dynamic Display Injection Time
Engine runs at idle 4.3 ~ 4.43 MS
Injector 1 Check cylinders
• Warmed up the en-
Injector 2 which affect idling,
gine for few minutes
Actuator test Idling condition be-
Injector 3 • Set Engine at idling
comes different (be-
Injector 4 speed
comes unstable)
DOIMC13AR11048

FUEL 13A
FUEL PUMP RELAY WCH13ASHOOT11011
DOIMC13AR11013
OPERATION
The fuel pump is driven when the engine is cranking and running.

13A FUEL
When the engine is cranking or in running condition, the power transistor of engine control unit is
turned ON to supply power to the engine control relay. This causes the engine control relay switch
to turn ON, and current is supplied from the ignition switch via the engine control relay to drive the
fuel pump relay to run the fuel pump motor.

codes tion
Fuel Pump Relay
P025A Open circuit Engine is running
Open Circuit
• Engine must be
Fuel Pump Relay
Short circuit to ON first.
P025C Short Circuit to Engine is running
ground • The fuel pump
Ground
should be heard
Fuel Pump Relay to operate.
Short circuit to bat-
P025D Short Circuit to Engine is running
tery
Battery
Dynamic Display Fuel cut off (SAS) Engine is running at idle speed OFF / ON
Function PADT-II Display Check condition Condition
• Ignition switch: ON Pulse is felt
• Fuel pump Forced driving
Actuator Test Fuel Pump Relay Sound of operation is
Inspect according to both
the above conditions heard

FUEL 13A
DOIMC13AR11047
MISFIRE WCH13ASHOOT11084
OPERATION
Commonly, misfire is due to the incompleteness of burning mixture between air and fuel. This problem
may be either due to the malfunction of ignition coil or spark plug or leakage of air flow to the engine.
Consequently, the compression between air and fuel by piston is not in optimum (2–18° BTDC-engine
idling or 2–45° BTDC-engine at 2500 r/min ). The incompleteness of burning mixture results carbon
monoxide, a pollutant gas which can pollute the environment.

13A FUEL
Check condi-
Fault codes PADT-II display Symptom description Range of Check
tion
Random/multiple cylin- • Engine speed is ap- Engine is run-
P0300 Plausibility
der misfire detected prox. 500-4000 ning
Cylinder 1 misfire detec- r/min Engine is run-
P0301 Misfire on cylinder 1 • Engine is not crank-
ted ning
ing.
Cylinder 2 misfire detec- Engine is run-
P0302 Misfire on cylinder 2 Set conditions:
ted ning
• The crank angle
Cylinder 3 misfire detec- sensor detects an Engine is run-
P0303 Misfire on cylinder 3
ted abnormal engine ning
speed caused by
Cylinder 4 misfire detec- Engine is run-
P0304 Misfire on cylinder 4 misfire (one of the
ted ning
coils fails).
Catalyst damaging misfire
cylinder 1
cylinder 2
Dynamic Display Engine runs at idle 0 ~ 65535
cylinder 3
cylinder 4
potential

FUEL 13A
DOIMC13AR11034

13A FUEL
KNOCK SENSOR WCH13ASHOOT11005
DOIMC13AR11007
OPERATION
The detonation sensor converts cylinder block vibration caused by detonation into a voltage that is
proportional to intensity of vibration, and sends it to the engine control unit, which then provides
delay control of the ignition timing based on this signal.

FUEL 13A
Check condi-
tion
Knock control system • Ignition switch: ONEngine is run-
P0324 KNCK SPI failure
error • Excluding 60 ning
KNCK sensor basic fail- seconds after the Engine is run-
P0325 Knock sensor error ignition is turned to
ure ning
ON or immediately
after the engine
starts.
• Engine speed is ap-
prox. 5000 r/min or
more.
Set conditions:
The change in the
Relative Knock Signal KNCK sensor relative detonation/knock Engine is run-
P0326 sensor output
Diagnosis failure ning
voltage (detona-
tion/knock sensor
peak voltage at
each 1/2 revolution
of the crankshaft) is
less than 0.06 V for
200 times in succe-
sion.
Dynamic Display Anti Knock Control Status Ignition On OFF / ON

13A FUEL
DOIMC13AR11041

FUEL 13A
CRANKSHAFT SENSOR WCH13ASHOOT11006
DOIMC13AR11005
OPERATION
The crankshaft sensor senses the crank angle (piston position) of each cylinder, converts it into a pulse
signal and inputs it to the engine control unit, which then computes the engine speed and controls
the fuel injection timing and ignition timing based on the input signal.
Power to the crank angle sensor is supplied from the ignition switch (IG) and is earthed to the body.
The crank angle sensor generates a pulse signal as it repeatedly connects and disconnects between
5V voltage supplied from the engine control unit and earth.

13A FUEL
Check condi-
tion
crankshaft sensor failure crankshaft sensor fail-
Engine is run-
P0335 open or short circuit ure open or short
ning
diagnosis CRK_OC circuit
crankshaft signal miss- • Engine is running Engine is run-
crankshaft signal missing
ing Set conditions: ning
crankshaft signal im- crankshaft signal im- • Sensor output Engine is run-
plausible plausible voltage does not ning
crankshaft loss of syn- crankshaft synchroniz- change for 4 Engine is run-
P0336 seconds (no pulse
chronization diagnosis ation lost ning
crankshaft tooth num- wrong crankshaft signal input) Engine is run-
ber error diagnosis tooth number ning
crankshaft tooth period crankshaft tooth peri- Engine is run-
diagnosis od out of range ning
Function PADT-II Display Full name Check condition Standard value
Dynamic Dis- Target Wheel Adapt- Target Wheel Adapt- Idle speed (Engine runs
Performed
play ation ation for 5 minutes)
TROUBLESHOOTING PROSEDURE
DOIMC13AR11042

FUEL 13A
IGNITION COIL WCH13ASHOOT11010
DOIMC13AR11010

13A FUEL
OPERATION
When the ignition switch is turned ON, the primary current flows to the two primary coils, which are
integrated in ignition coil. When the power transistor of ECU (engine control unit) is turned OFF, the
primary current is shut off due to the open circuit between ECU (engine control unit) and the primary
coils. Consequently, a high voltage is induced to the secondary coils, which supply the high voltage
to spark plugs.
When the power transistor of ECU (engine control unit) turns ON, the primary current will flow from
battery to ECU (engine control unit) through primary coils. The turn ON and OFF of power transistor
inside the ECU (engine control unit) is determined by the camshaft sensors, which is incorporated inside
the crankshaft. The detection of crankshaft position provides ignition to be occurred at the most ap-
propriate timing in response to the engine operation conditions.
Check condi-
tion
Ignition Coil 1 open cir- Engine is run-
P0351
cuit ning
P0352
cuit ning
Open circuit
P0353
cuit ning
P0354 • Engine speed is ap-
cuit ning
prox. 500-4000
Ignition Coil 1 short cir- r/min . Engine is run-
cuit to ground • Engine is not ning
Ignition Coil 1 short cir- cranking. Engine is run-
cuit to battery Set conditions: ning
Ignition Coil 3 short cir- • The crank angle Engine is run-
P2303 Short circuit to ground sensor detects an
cuit to ground ning
Ignition Coil 3 short cir- abnormal engine Engine is run-
P2304 Short circuit to plus speed caused by
cuit to battery ning
misfire (one of the
Ignition Coil 4 short cir- coils fails). Engine is run-
cuit to ground ning
Ignition Coil 4 short cir- Engine is run-
cuit to ground ning
Ignition On 0 °C (32 °F) CA IGN OFF
Dynamic Display Ignition Timing 9.2 °C (48.56 °F) ~ 11.7 °C
Engine runs at idle
(53.06 °F) CA

FUEL 13A
DOIMC13AR11046
CATALYTIC SYSTEM WCH13ASHOOT11086
DOIMC13AR11107
OPERATION
Catalytic converter is designed specifically to reduce the pollution air due to the pollutant gases (i. e.
carbon monoxide), resulted from the burning mixture of air and fuel. It removes the gases from the
engine to ensure that the burning mixture of air and fuel are in optimum condition. Basically, the
catalytic converter system consists of primary catalytic converter and secondary catalytic converter.
The primary catalytic converter ensures that all the gases are removed from the engine while the
secondary catalytic converter checks whether the gases is totally removed.

13A FUEL
Fault Symptom Descrip-

PADT-II Display Range of Check Check Condition
Codes tion
• Engine speed is
approx.
500-4000 r/min
Catalyst system effi- .
0420 ciency below Catalyst efficiency • Engine stumbles Engine is running
threshold when the cata-
lytic converter
connector is
plugged out.
Catalyst temperat-
Dynamic Display Engine runs at idle 50 ~ 950 °C (122 ~ 1742 °F)
ure model
DOIMC13AR11035

FUEL 13A
CANNISTER PURGE SOLENOID VALVE WCH13ASHOOT11015
DOIMC13AR11015
OPERATION
The cannister purge solenoid valve is an ON-OFF type of one which controls introduction of purge air
from the cannister into the intake air plenum.
The battery power is supplied to the cannister purge solenoid valve through main relay. When the
cannister purge solenoid valve turns ON the power transistor in the unit, current flows to the coil,
introduction purge air.

13A FUEL
Check Ccondi-
tion
Present electrical Can- • Engine is checking
Cannister purge solen- nister purge solenoid Set conditions Engine is run-
P0444
oid valve Open Circuit valve failure open cir- (when engine is ning
cuit cold): 40 °C (104
Present electrical can- °F) or less.
Cannister Purge Solen-
nister purge solenoid • Applied vacuum at Engine is run-
P0458 oid Diagnostic Short Cir- 53 kPa (7.54 psi, 16
valve failure short cir- ning
cuit to Ground in.Hg) .
cuit to ground
• Engine is checking
Set conditions
Present electrical can- (when engine is
Cannister Purge Solen-
nister purge solenoid hot): 80 °C (176 °F) Engine is run-
P0459 oid Diagnostic Short Cir-
valve failure short cir- or higher ning
cuit to Battery
cuit to battery • Applied vacuum at
53 kPa (7.54 psi, 16
in.Hg) .
Ign on 0.00 %
Dynamic Display Purge Duty Cycle
Engine runs at idle 0.04 %
Purge Duty Cycle = X %
(X value increase from
0~100%)
Actuator Test Purge valve Ignition On
Sound of operation can
be heard when solenoid
valve is driven

FUEL 13A
DOIMC13AR11051

13A FUEL
ENGINE FAN WCH13ASHOOT11009
DOIMC13AR11012
OPERATION
The power transistor inside the engine-ECU turns the fan motor relay on and off.
When the engine control unit turns the power transistor ON, it supplies the power to the radiator
fan relays. This causes the relay to turn ON, and current is supplied from the ignition switch via these
relays to drive the motor which are connected to them.

FUEL 13A
Check condi-
tion
Engine is run-
P0480 Fan 1 Open circuit Open circuit Set conditions: ning and A/C
• Engine and A/C switch is On
switch must be ON Engine is run-
Fan 1 Short circuit To
P0691 Short circuit to ground first. ning and A/C
ground
• The fan motor switch is On
should be heard to Engine is run-
Fan 1 Short circuit To operate.
P0692 Short circuit to battery ning and A/C
Battery
switch is On
Sound of operation can
Actuator Test Fan 1 Ignition ON be heard when purge
valve is driven
DOIMC13AR11045

13A FUEL
VEHICLE SPEED SIGNAL [ A/T ] WCH13ASHOOT11023
DOIMC13AR11025
OPERATION
The vehicle speed is generated by the wheel speed sensor which is located at the vehicle’s wheel. It
calculates the vehicle speed based upon the rotating speed of the vehicle’s wheel via magnetic field..
The vehicle speed signal to meter combination, ECU and TCU via CAN bus.

FUEL 13A
Symptom descrip-
Fault codes PADT-II Display Range of check Check condition
tion
P0500 Vehicle Speed Sensor VS sensor defective • Ignition switch: Engine is running
ON.
• Excluding 60
seconds after
the ignition is
turned to ON
or immediately
after the en-
gine starts.
• Idle switch:
OFF.
• Engine speed is
Vehicle Speed Correlation 3000 r/min or
P215A VS CAN not valid more. Engine is running
Not Valid
• Driving under
high engine
load condi-
tions. Set condi-
tions:
• Sensor output
voltage does
not change for
4 seconds (no
pulse signal in-
put).
Dynamic Display Vehicle Speed Ignition ON 0 km/h (0 mph)

13A FUEL
DOIMC13AR11059

FUEL 13A
VEHICLE SPEED SIGNAL [ M/T ] WCH13ASHOOT11029
DOIMC13AR11026
OPERATION
The vehicle speed is generated by the speed sensor.It send’s the signal to meter combination.
The meter combination convert the vehicle speed signal to CAN for after controler usage.

13A FUEL
Symptom descrip-
tion
P0500 Vehicle Speed Sensor VS sensor defective • Ignition switch: Engine is running
ON.
• Excluding 60
seconds after
the ignition is
turned to ON
or immediately
after the en-
gine starts.
• Idle switch:
OFF.
• Engine speed is
Vehicle Speed Correlation 3000 r/min or
P215A VS CAN not valid more. Engine is running
Not Valid
• Driving under
high engine
load condi-
tions. Set condi-
tions:
• Sensor output
voltage does
not change for
4 seconds (no
pulse signal in-
put).
Dynamic Display Vehicle Speed Ignition ON 0 km/h (0 mph)

FUEL 13A
DOIMC13AR11060

13A FUEL
BRAKE LIGHT SWITCH (Stop lamp switch) WCH13ASHOOT11077
DOIMC13AR11018

FUEL 13A
OPERATION
The brake light switch operates when the pedal is pressed. It signals the brake lamp to ON once the
pedal brake is pressed. The power from battery is supplied to the brake light switch and is connected
to the ECU-engine control unit.
Check condi-
tion
Set conditions:
• Pedal brake
pressed-brake light
Engine is run-
P0504 Brake Switch Error plausibility ON.
ning
• Pedal brake re-
leased-brake light
OFF.
DOIMC13AR11058

13A FUEL
ENGINE SPEED SIGNAL [ A/T ] WCH13ASHOOT11030
DOIMC13AR11023
OPERATION
The engine speed sensor which is located between ignition system and speedometer converts the
engine speed into a pulse and inputs it to the meter combination, which then provides the idle speed
control, etc.based on this signal.
The engine speed sensor generates the engine speed signal by repeatedly opening and closing between
the voltage of about 12V applied from the ignition system to meter combination.

FUEL 13A
Symptom descrip-
Fault codes PADT-II Display Range of Check Check condition
tion
Engine speed at idle is below Present ISC_LOW • Ignition switch:
calculated idle speed target failure ON.
• Excluding 60
seconds after
the ignition is
turned to ON
or immediately
after the en-
gine starts.
• Idle switch:
OFF.
• Engine speed is
3000 r/min or
Engine speed at idle is above Present ISC_HIGH more.
calculated idle speed target failure • Driving under
high engine
load condi-
tions. Set condi-
tions:
• Sensor output
voltage does
not change for
4 seconds (no
pulse signal in-
put).
Engine run at idle, a/c off ± 850 rpm
Dynamic Display Engine speed
Engine run at idle, a/c on ± 850 rpm

13A FUEL
DOIKC13AR09043

FUEL 13A
ENGINE SPEED SIGNAL [ M/T ] WCH13ASHOOT11031
DOIMC13AR11024
OPERATION
The engine speed is generated by the pulse generator which is located at the manual Transmission
Assembly. It calculates the engine speed based upon the manual Transmission speed.
The engine speed signal is generated by repeatedly opening and closing between the voltage of about
5V applied from the engine control unit-ECU and earth.

13A FUEL
Symptom descrip-
Fault codes PADT-II Display Range of Check Check condition
tion
Engine speed at idle is below Present ISC_LOW • Ignition switch:
calculated idle speed target failure ON.
• Excluding 60
seconds after
the ignition is
turned to ON
or immediately
after the en-
gine starts.
• Idle switch:
OFF.
• Engine speed is
3000 r/min or
Engine speed at idle is above Present ISC_HIGH more.
calculated idle speed target failure • Driving under
high engine
load condi-
tions. Set condi-
tions:
• Sensor output
voltage does
not change for
4 seconds (no
pulse signal in-
put).
Engine run at idle, a/c off ± 750 rpm
Dynamic Display Engine speed
Engine run at idle, a/c on ± 750 rpm

FUEL 13A
DOIKC13AR09043

13A FUEL
IMMOBILISER WCH13ASHOOT11082
DOIMC13AR11017
OPERATION
Immobiliser is designed to provide protection from automobile thefts. This system is equipped with
a software to lock the engine control unit. The engine control unit can only operate if the touch key
is placed at the touch key receiver which is integrated with key ring antenna. Once the touch key is
contacted with touch key receiver, and the right code is sent to the ECU which enables the engine to
start.
Check condi-
tion
immobilizer failure
P0513 Immobilizer Locked due to wrong authen- Ignition On
• Check the key ring
tication process
connection with
immobilizer failure engine ECU
Communication with
P0633 due to no communica- Ignition On
Transponder Missing
tion with transponder

FUEL 13A
DOIMC13AR11057

13A FUEL
POWER SUPPLY WCH13ASHOOT11016
DOIMC13AR11020

FUEL 13A
OPERATION
The engine ECU must be earthed properly to ensure its operation works properly. The connection to
the power supply from battery must be also checked whether it is properly connected.
Check condi-
Fault codes PADT-II Display Symptom description Range of check
tion
P0562 Battery voltage too low Battery voltage too low • No power supply to Ignition On
Battery voltage too Battery voltage too engine-ECU.
P0563 Ignition On
high high • Defective earth cir-
Battery voltage too Battery voltage too cuit of engine-ECU.
P1793 high high • Defective engine- Ignition On
Battery voltage too low Battery voltage too low ECU. Ignition On
DOIMC13AR11052

13A FUEL
ENGINE CONTROL UNIT WCH13ASHOOT11079
DOIMC13AR11027
OPERATION
Engine Control Unit-ECU is a unit which controls the engine system of car. It contacts with the PADT-
II to signal any problems that are occured in engine system.
The engine ECU must be earthed properly to ensure its operation works properly. The connection to
the power supply from battery must be checked whether it is properly connected.
Check condi-
Fault codes PADT-II Display Symptom description Range of check
tion
ECU Warm-reset dia- • Disconnect the
P0604 ECU Warm Reset Ignition ON
gnosis terminal battery
SPI Bus communica- before carrying
P0606 ECU Internal Fault out the test. Ignition ON
tion
• Wait for 5
P060A ECU Internal Fault - General General monitoring Ignition ON
minutes after dis-
ECU Internal Fault - Pro- connecting the
P060C GENERAL Ignition ON
cessor monitoring terminal battery.

FUEL 13A
DOINC13AR09079

13A FUEL
STARTER CONTROL WCH13ASHOOT11014
DOIMC13AR11011
OPERATION
The starter control is driven when the engine is cranking and while the engine is running.

FUEL 13A
When the engine is cranking or running, the engine control unit turns the power transistor ON, which
supplies the power to the starter relay. This causes the starter relay to turn ON and current is supplied
from the ignition switch via the starter relay to drive the starter motor.
Fault codes PADT-II Display Symptom description Range of Check Check condition
Starter Relay Open Cir-
P0615 Open circuit • Engine must be Ignition ON
cuit
ON first.
Starter Relay Short Cir- Short circuit to
P0616 • The starter motor Ignition ON
cuit to Ground ground
should be heard
Starter Relay Short Cir- Short circuit to bat- to operate.
P0617 Ignition ON
cuit to Battery tery
DOIMC13AR11050

13A FUEL
SENSOR SUPPLY WCH13ASHOOT11093
DOIMC13AR11104
OPERATION
Engine ECU check to throttle position sensor, pedal voltage sensor, TMAP sensor and Camshaft sensor
power voltage for abnormal.

FUEL 13A
Check condi-
tion
• Throttle position
sensor 1 power voltage
Sensor reference voltage less than 4.4 V
P0642
‘A’ circuit LOW • Pedal voltage sensor
1 power voltage less
than4.4 V
• Throttle position
sensor 1 power voltage
Sensor reference voltage more than 5.59 V
P0643
‘A’ circuit HIGH • Pedal voltage sensor
1 power voltage more
than5.59 V • Battery voltage12~14
Ignition ON
V
• TMAP sensor power
voltage less than 4.4 V
Sensor reference voltage
P0652 • Camshaft sensor
‘B’ circuit LOW
power voltage less
than4.4 V
• TMAP sensor power
voltage more than
Sensor reference voltage 5.59 V
P0653
‘B’ circuit HIGH • Camshaft sensor
power voltage more
than5.59 V

13A FUEL
DOIMC13AR11105

FUEL 13A
AIR COND CLUTCH WCH13ASHOOT11020
DOIMC13AR11019
OPERATION

13A FUEL
When an A/C ON signal is input to engine-ECU, the engine-ECU carries out control of the stepper
motor integrated with throttle body actuator, and also operates the A/C compressor magnetic clutch.
Fault
PADT-II Display Symptom description Range of check Check Condition
Codes
Air Condition Clutch, • Engine is running Engine is running
P0645 Open circuit
Open Circuit at idle speed.
Air Condition Clutch, • A/C switch is ON -
P0646 Short Circuit To Short circuit to ground Blower Relay oper- Engine is running
Ground ates.
Air Condition Clutch, • The compressor
P0647 Short Circuit To Bat- Short circuit to plus fan can be heard Engine is running
tery once it operates.

OFF
Dynamic Display Air cond request signal Ignition ON
ON

FUEL 13A
DOIMC13AR11054

13A FUEL
VIM (VACCUM ACTUATOR) [IAFM] WCH13ASHOOT11019
DOIMC13AR11029
OPERATION
The Vacuum actuator control the intake of air in the VIM module. It controls the air flow in the intake
manifold either to short-runner or long-runner during certain engine rpm to increase the driveability
performance.
Function of Va- Intake manifold Intake manifold

Engine speed Remarks
cuum actuator valve condition condition
OFF OPEN LONG-RUN Below 4,500 rpm Engine running and
engine temperature
must above 60 °C (140
ON CLOSE SHORT-RUN Above 4,500 rpm °F), and engine run at
4,500 rpm.

FUEL 13A
Check condi-
Fault codes PADT-II Display Symptom description
tion
P0660 VIM Actuator Electrical Power Engine run-
VIM Actuator open circuit
Stage Diagnosis ning and en-
VIM Actuator Electrical Power VIM Actuator short circuit to gine temperat-
P0661 ure must
Stage Diagnosis ground
above 60 °C
VIM Actuator Electrical Power (140 °F), and
P0662 VIM Actuator short circuit to plus engine run at
Stage Diagnosis
4,500 rpm .
Camshaft Control Active Engine running and Active
Intake Manifold Control engine temperature
Active
Dynamic Display Active must above 60 °C
Diagnostic Distance (140 °F), and engine
run at 4,500 rpm. KM_MIL
Counter Since MIL On
DOIMC13AR11053

13A FUEL
MAIN RELAY WCH13ASHOOT11087
DOIMC13AR11103

FUEL 13A
OPERATION
The engine control relay (MAIN RELAY) control many engine devices eg. Fuel pump cannister purge
solenoid valve, ignition coil, injectors, oxygen sensor etc.
When the engine is cracking or in running condition, the power transistor of engine control unit (ECU)
is turned ON to supply power to the engine control relay. This causes the engine control relay to turn
ON, and current is supplied from the ignition switch via engine control relay to drive the engine
devices.

PADT-II Display Range of check Check condition
codes tion
Main relay input Main relay input ol
P0685
open circuit electrical diagnosis
Main relay input
Main relay input scg
P0686 short circuit to
electrical diagnosis
ground
Main relay input
Main relay input scp
P0687 short circuit to bat-
electrical diagnosis
tery Engine must be ON
Engine is running
Main relay on out- Main relay on out- first
P0689 put diagnosis put diagnosis plaus-
plausibility ibility
Main relay off out- Main relay off out-
P0690 put diagnosis put diagnosis plaus-
plausibility ibility
Main relay switch Main relay switch
P2510
on to slow on to slow

13A FUEL
DOIMC13AR11033

FUEL 13A
TRANSMISSION CONTROL UNIT (CVT) WCH13ASHOOT11022
DOIMC13AR11110
OPERATION
Transmission control Unit (CVT-TCU) is a unit which controls the transmission system of car. It contacts
with the ECU to signal any problems occurred in transmission system. The ECU sends the problems to
the PADT-II, which gives the repairers to identify its defectiveness.
The connection of CVT-TCU to the power supply from battery must be checked whether it is properly
connected.
Symptom descrip-
tion
One of the follow-
ing causes may be
suspected:
• No power
supply to
CVT.
• Defective of
Transmission control unit Transmission limp transmission
limp home diagnosis home unit -CVT.
• CAN bus is off
• CAN ECU
communica-
tion failed
• CAN engine
torque signal
error
Dynamic Display Gear Lever Position Ignition ON D / P/N

13A FUEL
DOIMC13AR11112

FUEL 13A
P/N SWITCH WCH13ASHOOT11092
DOIMC13AR11062
OPERATION
1. For security, the shift lever position must be in either P or N position in order for the engine can
be started.
2. CVT - TCU sends the shift lever position to engine ECU via CAN . A back-up signal is send via
hardwire (pin no 92) from CVT-TCU to engine ECU
3. Engine ECU to set an error when it detects differences between CAN signal and the hardwire
signal.
Check condi-
tion
• Ignition switch ON
position
P0850 P/N switch Plausibility Plausible Value Ignition ON
• Can voltage measure-
ment 0~3 V

13A FUEL

Dynamic Display Gear position Ignition ON D, P/N
DOIMC13AR11101

FUEL 13A
PEDAL/BRAKE SWITCH WCH13ASHOOT11091
DOIMC13AR11061

13A FUEL
OPERATION
The engine ECU detects that accelerator pedal and brake pedal are both pressed for a calculated
amount of time.
Check condi-
tion
While driving, pedal
assembly mechanically • Plausibility
Brake pedal position /
stuck (voltage output brake error
P2299 accelerator pedal posi- Engine is running
stay fixed) and follow • Accelarator
tion incompatible
by a long application pedal stuck
of the brake
Engine Idling (No Load) 0%
Dynamic Display Accelerator pedal position
Engine Idling (Full Throttle) 100%

FUEL 13A
DOIMC13AR11102

13A FUEL
CAN COMUNICATION WCH13ASHOOT11081
DOIMC13AR11016
OPERATION
Engine control unit monitors and interacts with the Transmission Control Unit to ABS and meter
combination ensure that the transmission unit operates in a good condition. By plugging the PADT-
II to the ECU connector, the errors in the control unit area can be detected easily.

FUEL 13A
Fault
PADT-II Display Symptom description Range check Check condition
codes
CAN Diagnosis -
U0073 CAN bus off Engine is running
Buss Off
Error in the respect-
CAN Diagnosis - Lost
ive Control Unit (CU)
U0100 Communication Engine is running
communicating on
with ECU
the CAN-HS bus
CAN Diagnosis - Lost • Check the wiring
U0101 Communication harness between Engine is running
communicating on
with TCU ECU connector
the CAN-HS bus
and TCU connect-
Error in the respect- or.
communicating on
with ABS/ESP
the CAN-HS bus
communicating on
with meter cluster
the CAN-HS bus
DOIMC13AR11056

13A FUEL
/ 118 TROUBLE SYMPTOM
TROUBLE SYMPTOM WCH13ASHOOT11094
INSPECTION CHART FOR TROUBLE SYMPTOMS

Inspection
Trouble symptom procedure Reference page
No.
Communication with all
1 13A/121
systems is not possible
Communication with PADT-II is
impossible Communication with en-
gine-ECU only is not pos- 2 13A/121
sible
The engine warning lamp
does not illuminate right
after the ignition switch 3 13A/122
Engine warning lamp and related is turned to the ON posi-
parts tion
The engine warning lamp
remains illuminating and 4 13A/123
never goes out
No initial combustion
5 13A/124
(starting impossible)
Initial combustion but no
Starting complete combustion 6 13A/125
(starting impossible)
Takes too long time to
7 13A/126
start (improper starting)
Unstable idling (Rough
8 13A/127
Idling, hunting )
Idling speed is high (Im-
Idling stability (Improper idling) 9 13A/128
proper idling speed)
Idling speed is low (Im-
10 13A/129
proper idling speed)
When the engine is cold,
11 13A/130
it stalls at idling (Die out)
When the engine be-
comes hot, it stalls at id- 12 13A/131
Idling stability (Engine stalls) ling (Die out)
The engine stalls when
13 13A/132
starting the car (Pass out)
The engine stalls when
14 13A/133
decelerating

FUEL 13A
TROUBLE SYMPTOM / 119
Inspection
Trouble symptom procedure Reference page
No.
Hesitation, sag or stumble 15 13A/134
The feeling of impact or
vibration when accelerat- 16 13A/135
ing
The feeling of impact or
Driving vibration when decelerat- 17 13A/136
ing
Poor acceleration 18 13A/137
Surge 19 13A/138
Knocking 20 13A/139
Dieseling 21 13A/140
Too high CO and HC concentration when idling 22 13A/141
Low alternator output voltage (approx. 12.3 V ) 23 13A/142
Power supply system and ignition switch-IG system 24 13A/142
Fuel pump system 25 13A/143
Ignition switch-ST system <M/T> 26 13A/144
Ignition switch-ST and inhibitor switch system <A/T> 27 13A/145
A/C switch and A/C relay system 28 13A/146
Fan motor relay system (Radiator fan, A/C condenser fan) 29 13A/147
Tank purge valve system 30 13A/148
PADT-II: Inspection of no initial combustion 31 13A/149
Ignition system: Inspection of no initial combustion 32 13A/150
PADT-II: Check if incomplete combustion occurs 33 13A/151
Check if hunting occurs 34 13A/152
PADT-II: Check if idling speed is unstable 35 13A/153
PADT-II: Engine stalling inspection when the engine is
36 13A/154
warmed up and idling
PADT-II: Check if hesitation, sag, stumble or poor accelera-
37 13A/155
tion occurs
PADT-II: Check if surge occurs 38 13A/156
Check the engine-ECU power supply and earth circuit 39 13A/157
Check fuel pump circuit 40 13A/158
Check fuel pump drive control circuit 41 13A/159
Check throttle body actuator (TBA) output circuit 42 13A/160
Check injector control circuit 43 13A/161
Check ignition coil and power transistor unit circuit 44 13A/162

13A FUEL
PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) WCH13ASHOOT11095
Items Symptom
The starter is used to crank the engine, but there is no
Won't start combustion within the cylinder, and the engine soon
stalls.
Starting
There is combustion within the cylinder, but then the
Fires up and dies
engine soon stalls.
Hard starting Engine starts after cranking a while.
Hunting Engine speed doesn't remain constant; changes at idle
Usually, a judgement can be based upon the movement
of the tachometer pointer, and the vibration transmit-
Rough idle
ted to the wheel, shift lever, body, etc.
This is called rough idle.
Idling stabil-
Incorrect idle speed The engine doesn't idle at the usual correct speed.
ity
The engine stalls when the foot is taken from the ac-
Engine stalls (Die out) celerator pedal, regardless of whether the vehicle is
moving or not.
The engine stalls when the accelerator pedal is de-
Engine stalls (Pass out)
pressed or while it is being used.
“Hesitation” is the delay in response of the vehicle
speed (engine speed) that occurs when the accelerator
Hesitation Sag is depressed in order to accelerate from the speed at
which the vehicle is now travelling, or a temporary in
vehicle speed serious hesitation is called “sag”.
Poor acceleration is inability to obtain an accelerator
corresponding to the degree of throttle opening, even
Poor acceleration
though acceleration is smooth, or the inability to reach
Driving maximum speed.
Engine speed increase is delayed when the accelerator
Stumble
pedal is initially depressed for accelerated.
The feeling of a comparatively large impact or vibra-
Shock
tion when the engine is accelerated or decelerated.
The repeated surging ahead during constant speed
Surge
travel or during variable speed travel.
A sharp sound like a hammer striking the cylinder walls
Knocking
during and which adversely affects driving.
The condition in which the engine continues to run
Stopping Run on (“Dieseling”) after the ignition switch is turned to OFF. Also called
“Dieseling”.

FUEL 13A
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS / 121
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS WCH13ASHOOT11033
INSPECTION PROCEDURE 1
Communication with PADT-II is not possible (Communication with all systems is not possible )
Communication with PADT-II is not possible (Communication with
Probable cause
all systems is not possible )
• Malfunction of the connect-
The cause is probably a defect in the power supply system (including or.
earth) for the diagnosis line. • Malfunction of the harness
wire.
DOIMC13AR11063
INSPECTION PROCEDURE 2 WCH13ASHOOT11034
PADT-II Communication with engine-ECU is impossible

PADT-II — Communication with engine-ECU is
Probable cause
impossible
One of the following causes may be suspected:
• No power supply to engine-ECU. • Malfunction of engine-ECU power supply circuit.
• Defective earth circuit of engine-ECU. • Malfunction of engine-ECU.
• Defective engine-ECU. • Open circuit between engine-ECU and diagnosis
• Improper communication line between en- connector.
gine-ECU and PADT-II.

13A FUEL
/ 122 INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
DOIMC13AR11064
The engine warning lamp does not illuminate right after the ignition switch is turned to the ON
position
The engine warning lamp does not illuminate right after
Probable cause
the ignition switch is turned to the ON position
Because there is a burnt-out, the engine-ECU causes the
engine warning lamp to illuminate for 5 seconds immedi- • Malfunction at LED.
ately after the ignition switch is turned to ON. • Malfunction of engine-ECU.
If the engine warning lamp does not illuminate immedi- • Defective warning lamp circuit.
ately after the ignition switch is turned to ON, one of the • Malfunction at Meter Combination.
malfunctions listed at right has probably occurred.

FUEL 13A
DOIMC13AR11065
The engine warning lamp remains illuminating and never goes out.
The engine warning lamp remains illuminating and never goes
Probable cause
out.
• Short-circuit between the engine
warning lamp and engine-ECU.
In cases such as the above, the cause is probably that the en- • One of the sensors is having
gine-ECU is detecting a problem in a sensor or actuator, or that problem.
malfunctions listed at right has occurred. • Malfunction of actuator.
• Malfunction of engine-ECU.

13A FUEL
DOIMC13AR11066
No initial combustion (starting impossible)

No initial combustion (starting impossible) Probable cause
In cases such as the above, the cause is probably • Malfunction of the ignition system.
that a spark plug is defective, or that the supply • Malfunction of the fuel pump system.
of fuel to the combustion chamber is defective. • Malfunction of the injectors.
In addition, foreign materials (water, kerosene, • Malfunction of engine-ECU.
etc.) may be mixed with the fuel. • Foreign materials in fuel.

FUEL 13A
DOIMC13AR11067
Initial combustion but no complete combustion (starting impossible)

Initial combustion but no complete combustion (starting Probable cause
impossible)
• Malfunction of the ignition sys-
tem.
• Malfunction of the injectors sys-
In such cases as the above, the cause is probably that the spark tem.
plugs are generating sparks but the sparks are weak, or the • Malfunction of the throttle body
initial mixture for starting is not appropriate. actuator system.
• Malfunction of engine-ECU.
• Foreign materials in fuel.
• Poor compression.

13A FUEL
DOIMC13AR11068
Takes too long time to start (Incorrect Starting)

Takes too long time to start (Incorrect Starting) Probable cause
In cases such as the above, the cause is probably • Malfunction of the ignition system.
that the spark is weak and ignition is difficult, • Malfunction of the injectors system.
the initial mixture for starting is not appropriate, • Inappropriate gasoline use.
or sufficient compression pressure is not being • Poor compression.
obtained.

FUEL 13A
DOIMC13AR11069
Unstable idling (Rough idling, hunting)

Unstable idling (Rough idling, hunting) Probable cause
• Malfunction of the ignition system.
In cases such as the above, the cause is probably • Malfunction of air-fuel ratio control system.
that the ignition system, air/fuel, accelerator • Malfunction of the throttle body actuator sys-
pedal sensor or compression pressure is defect- tem.
ive. • Malfunction of the tank purge valve system.
Because the range of possible causes is broad, • Poor compression.
inspection is narrowed down to simple items. • Drawing air into exhaust system.

13A FUEL
DOIMC13AR11070
Idling speed is high (Improper idling speed)

Idling speed is high (Improper idling speed) Probable causes
• Malfunction of the throttle body
actuator.
In such cases as the above, the cause is probably that the in- • Malfunction of the engine coolant
take air volume during idling is too great. temperature sensor.
• The throttle valve area might be
dirty.

FUEL 13A
DOIMC13AR11071
Idling speed is low (Improper idling speed )

Idling speed is low (Improper idling speed) Probable cause
• Malfunction of the engine coolant temperature
sensor.
In such cases as the above, the cause is probably • Throttle body might be dirty.
that the intake air volume during idling is too • Ignition System or inhibitor switch (for auto
small. transmission) might be not working in normal
condition.
• Malfunction of the throttle body actuator.

13A FUEL
DOIMC13AR11072
When the engine is cold, it stalls at idling (Die out)

When the engine is cold, it stalls at idling (Die
Probable cause
out)
In such cases as the above, the cause is probably • Malfunction of the throttle body actuator.
that the air/fuel mixture is inappropriate when • Malfunction of the injector system.
the engine is cold, or that the intake air volume • Malfunction of the ignition system.
is insufficient. • Malfunction of coolant temperature sensor.

FUEL 13A
DOIMC13AR11073
When the engine is hot, it stalls at idling (Die out)

When the engine is hot, it stalls at idling (Die out) Probable cause
• Malfunction of the throttle body actuator.
In such cases as the above, the cause is probably • Malfunction of air-fuel ratio control system.
that ignition system, the air/fuel mixture. • Malfunction of the ignition system.
In addition, if the engine suddenly stalls, the cause • Drawing air into intake system.
may also be a defective connector contact. • Improper connector contact.

13A FUEL
DOIMC13AR11074
The engine stalls when starting the car (Pass out)

The engine stalls when starting the car (Pass out) Probable cause
In cases such as the above, the cause is probably misfiring due • Malfunction of the ignition system.
to a weak spark, or an inappropriate air/fuel mixture when • Malfunction of tank purge valve.
the accelerator pedal is depressed. • Drawing air into intake system.

FUEL 13A
DOIMC13AR11075
The engine stalls when decelerating

The engine stalls when decelerating Probable cause
In cases such as the above, the cause is probably
that the intake air volume is insufficient due to • Malfunction of the throttle body actuator.
the defective of throttle body actuator.

13A FUEL
DOIMC13AR11076
Hesitation, sag or stumble

Hesitation, sag or stumble Probable cause
• Malfunction of air-fuel ratio con-
trol system.
In cases such as the above, the cause is probably that ignition • Malfunction of the fuel supply
system, air/fuel mixture or compression pressure is defective. system.
• Malfunction of the solenoid valve
evaporation system.
• Poor compression.

FUEL 13A
DOIMC13AR11077
The feeling of impact or vibration when accelerating

The feeling of impact or vibration when
Probable cause
accelerating
In cases such as the above, the cause is probably
that there is an ignition leak accompanying the • Malfunction of the ignition system.
increase in the spark plug demand during accel-
eration.

13A FUEL
DOIMC13AR11078
The feeling of impact of vibration when decelerating

The feeling of impact of vibration when
Probable cause
decelerating
Malfunction of the throttle body actuator sys- • Malfunction of the throttle body actuator system.
tem is suspected.

FUEL 13A
DOIMC13AR11079
Poor acceleration
Poor acceleration Probable cause
• Malfunction of the throttle body actu-
ator system.
Defective ignition system, abnormal air-fuel ratio, poor • Malfunction of the accelerator pedal
compression pressure etc. are suspected. sensor.
• Ignition timing is set incorrectly.

13A FUEL
DOIMC13AR11080
Surge
Surge Probable cause
Defective ignition system, abnormal air-fuel ratio, etc. • Malfunction of air-fuel ratio control sys-
are suspected. tem.
• Injectors do not work.

FUEL 13A
DOIMC13AR11081
Knocking
Knocking Probable cause
In cases as the above, the cause is probably that the • Inappropriate heat valve of the spark plug.
detonation control is defective or the heat valve of • Malfunction of knock sensor.
the spark plug is inappropriate.
Check the following items.
• Spark plugs
• Check if foreign materials (water, alcohol, etc.) got into fuel.
• Check the knock sensor

13A FUEL
DOIMC13AR11082
Dieseling
Dieseling Probable cause
Fuel leakage from injectors is suspected. • Fuel leakage from injectors.
DOIHC13AR05148

FUEL 13A
Too high CO and HC concentration when idling

Too high CO and HC concentration when idling Probable cause
• Malfunction of the air-fuel control system.
Abnormal air-fuel ratio is suspected. • Front and rear oxygen sensor do not work.
• Deteriorated catalyst.
DOIMC13AR11083

13A FUEL
Low Alternator Output Voltage (Approx 12.3 V )

Low Alternator Output Voltage (Approx. 12.3 V ) Probable cause
• Malfunction of charging system (Refer to
GROUP 16-ENGINE ELECTRICAL FOR
The alternator may be defective, or malfunction, which CHARGING SYSTEM CHECK.).
are listed in the right column, may be suspected. • Short circuit in harness between alternat-
or G terminal and engine-ECU.
DOIMC13AR07226
Power supply system and ignition switch-IG system

Power supply system and ignition switch-IG system Probable cause
• Malfunction of the ignition switch.
When an ignition switch ON signal is input to the • Malfunction of the main relay.
engine-ECU, the engine-ECU turns the control relay • Improper connector contact, open circuit or
ON. This causes battery voltage to be supplied to short-circuited harness wire.
the engine-ECU, injectors and Ignition system. • Disconnected of the engine-ECU earth wire.
• Malfunction of the engine-ECU.

FUEL 13A
DOIMC13AR11084
Fuel pump system

Fuel pump system Probable cause
• Malfunction of the fuel pump relay.
The engine-ECU turns the fuel pump relay ON when the • Malfunction of the fuel pump.
engine is cranking or running, and this supplies power • Improper connector contact, open circuit
to drive the pump. or short-circuited harness wire.

13A FUEL
DOIMC13AR11085
Ignition switch-ST system [M/T]

Ignition switch-ST system [M/T] Probable cause
• Malfunction of ignition switch.
The ignition switch-ST inputs a HIGH signal to the engine- • Improper connector contact, open
ECU while the engine is cranking. The engine-ECU control circuit or short-circuit harness wire.
fuel injection, etc. during cranking based on this input. • Malfunction of the engine-ECU.

FUEL 13A
DOIMC13AR11086
Ignition switch-ST and inhibitor switch system [CVT]

Ignition switch-ST and inhibitor switch system [CVT] Probable cause
• The ignition switch-ST inputs a HIGH signal to the engine-ECU • Malfunction of ignition
while the engine is cranking. switch.
• The engine-ECU control fuel injection, etc. during based on • Malfunction of inhibitor
this input. switch.
• The inhibitor switch inputs the condition of the select lever, • Improper connector contact,
i.e. whether it is in P or N range or in some others range, or in open circuit or short-circuit
some others range, to the engine-ECU. harness wire.
• The engine-ECU controls steeper motor, which integrated in • Malfunction of the engine-
the throttle body actuator based on the input from inhibitor ECU.
switch.

13A FUEL
DOIMC13AR11106
A/C switch and A/C relay system

A/C switch and A/C relay system Probable cause
• When an A/C ON signal is input to engine- • Malfunction of A/C control.
ECU, the engine- ECU carries out control of • Malfunction of A/C switch.
the steeper motor integrated with throttle • Improper connector contact, open circuit or
body actuator, and also operates the A/C short-circuit harness wire.
compressor magnetic clutch. • Malfunction of the engine-ECU.

FUEL 13A
DOIMC13AR11087
Fan motor relay system (Radiator fan)

Fan motor relay system (Radiator fan) Probable cause
• Malfunction of fan motor relay.
• Malfunction of fan motor.
• The power transistor inside the engine-ECU turns • Improper connector contact, open circuit or
the fan motor relay on and off. short-circuit harness wire.

13A FUEL
DOIMC13AR11088
Tank purge valve system

Tank purge valve system Probable cause
• Malfunction of tank purge valve.
• Tank purge valve controls the purging of air from the • Improper connector contact, open
canister located inside the intake manifold. circuit or short-circuit harness wire.

FUEL 13A
DOIMC13AR11089
PADT-II: Inspection of no initial combustion

Inspection of no initial combustion Probable cause
• Malfunction of camshaft sensor
In such cases above, the the cause is probably malfunc- • Malfunction of crank angle sensor
tion of sensors and actuators as per next table • Malfunction of fuel pump system
• Malfunction of coolant temperature sensor

13A FUEL
DOIMC13AR11090
Ignition system: Inspection of no initial combustion

Inspection of no initial combustion Probable cause
The cumbustion is initiate by the ignition system, where signal • Malfunction of ignition system
is sent to engine ECU and the ECU turns the injectors and ignition • Malfunction of crank angle sensor
coil . • Malfunction of engine ECU

FUEL 13A
DOIMC13AR11091
PADT-II: Check if incomplete combustion occurs

In complete combustion occurs Probable cause
• Malfunction of fuel pump
In such cases, the cause is probably the malfunction of the • Malfunction of coolant temperature
sensor and actuators as per next column sensor
• Malfunction of ignition switch- starting

13A FUEL
DOIMC13AR11092
Check if hunting occurs

Hunting occurs Probable cause
In such cases, the cause is probably malfunction of • Malfunction of Throttle body actuator
sensor and actuator as items next column • Malfunction of air intake system

FUEL 13A
DOINC13AR09081
PADT-II: Check if idling speed is unstable

Idling speed is unstable Probable cause
• Malfunction of intake air temperature system
In such cases, the cause is probably malfunc- • Malfunction of coolant temperature sensor
tion of sensors and actuators as items in • Malfunction of purge solenoid valve
the next column • Malfunction of oxygen sensor
• Malfunction of Throttle body actuator

13A FUEL
DOIMC13AR11093
PADT-II : Engine stalling inspection when the engine is warmed up and idling
Engine stalling inspection when the engine is warmed up
Probable cause
and idling
In such cases, the cause is probably malfunction of sensors • Malfunction of throttle body actuator
and actuators as items in the next column • Malfunction of intake iar system

FUEL 13A
DOIMC13AR11093
PADT-II: Check if hesitation, sug, stumble or poor acceleration occurs

Check if hesitation, sug, stumble or poor acceleration occurs Probable cause
• Malfunction of throttle body actuator
• Malfunction of engine coolant tem-
In such cases, the cause is probably malfunction of sensor and
perature
actuator as items listed in the next column.
• Malfunction of tank purge valve
sensor

13A FUEL
DOIMC13AR11094
PADT-II: Check if surge occurs

Check if surge occurs Probable cause
In such cases, the cause is prob- • Malfunction of throotle body actuator
ably malfunction of the sensors • Malfunction of the combined MAP & MAT sensor
and actuators as listed in the • Malfunction of the tank purge valva
next column • Malfunction of the oxygen sensor

FUEL 13A
DOIMC13AR11094
Check the engine-ECU power supply and earth circuit

Check the engine-ECU power supply and earth
Probable cause
circuit
• In proper connector mating and condition
In such cases, the cause is probably as items listed • Fuse is blown
in the next column • Relay contact defective
• Harness is open circuit/ short circuit to ground

13A FUEL
DOIMC13AR11095
Check fuel pump motor circuit

Check fuel pump motor circuit Probable cause
• Malfunction of the fuel pump motor
In such cases, the cause is probably items listed in the • Fuel pump motor harness short circuit to
next column ground/ open circuit
• Malfunction of ECU

FUEL 13A
DOIMC13AR11096
Check the fuel pump relay drive circuit

Check the fuel pump relay drive circuit Probable cause
• Fuel pump relay contact defective
• Fuse blown
In such cases, the cause is probably as listed in the
• Fuel pump harness open circuit/ short circuit
next column
• Malfunction of fuel pump motor

13A FUEL
DOIMC13AR11097
Check throttle body actuator (TBA) output circuit

Check throttle body actuator (TBA) output
Probable cause
circuit
• Malfunction of throttle body actuator
In such cases, the cause is probably as listed • Throttle body actuator harness open circuit/ short cir-
in the next column cuit

FUEL 13A
DOIMC13AR11098
Check injector control circuit

Check injector control circuit Probable cause
• Malfunction of injectors
In such cases, the cause probably as items lis- • Missing signal from ECU
ted in the next column • Injectors harness open circuit/ open circuit

13A FUEL
DOIMC13AR11099
Check ignition coil and power transistor unit circuit

Check ignition coil circuit Probable cause
• Malfunction of ignition coil
In such cases, the probable cause is probably as items • Ignition coil harness open circuit/ short
listed in the next column circuit

FUEL 13A
DATA LIST / 163
DOIMC13AR11100
DATA LIST WCH13ASHOOT11026
DATA LIST REFERENCE TABLE

CAUTION
When shifting the select leaver to D range, the brake should be applied so that the vehicle does not
move forwards.
NOTE
(1) *
The idle switch out normally turns off when the voltage of the throttle body actuator is 50-100
mv higher than the voltage at the idle position. If the throttle position switch turns back on after
the throttle position sensor (integrated with the throttle body actuator) voltage has risen by 100
mv and the throttle valve has opened, the idle position switch and the throttle position sensor
(integrated with the throttle body actuator) need to be adjusted.
(2) *
In a new vehicle [driven approximately 500 km (310.68 mile) or less], the air intake plenum
pressure is sometimes 10% higher than the standard pressure.
(3) *
The injector drive time represents the time when the cranking speed is at 250 r/min or below
when the power supply voltage is 11 V .
(4) *
In a new vehicle [driven approximately 500 km (310.68 mile) or less], the injector drive time is
sometimes 10% longer than the standard time.
(5) *

13A FUEL
/ 164 DATA LIST
In a new vehicle [driven approximately 500 km (310.68 mile) or less], the step of the stepper
motor is sometimes 30 steps greater than the standard value.
CURR PADT– II DISPLAY CHECK CONDI- STANDARD

UNIT REMARKS
NAME TION VALUE
89~92 °C
Engine temperat-
1 Ign on (192.2~197.6 °C Engine coolant temperature
ure
°F)
Engine start tem- 20~100 °C
2 Ign on °C Initial starting temperature
perature (68~212 °F)
Intake air temper- 33~100 °C
3 Ign on °C Temperature at intake manifold
ature (91.4~212 °F)
Engine run at
±850 rpm
idle, a/c off
4 Engine speed rpm Engine speed at idle
Engine run at
±850 rpm
idle, a/c on
Idle speed set-
5 Ign on 850 rpm rpm Idle speed set-piont value
point
Engine run at
6 Engine load 0.26 ~ 0.31 — Engine load
idle
Ign on 1010 hpa
Intake manifold
7 Engine runs at hPa Pressure at intake manifold
pressure 410 hpa
idle
Ign on 8.63 %
Throttle body posi-
8 Engine runs at % TPS Throttle position
tion sensor (tps) 4.31 %
idle
Ign on ~ 0 °crk
9 Ignition timing Engine runs at °CRK Ignition timing degree crank
~ 9.2 °crk
idle
Ign on 0 ms
10 Injection time Engine runs at ms Injection timing
4.3 ~ 4.43 ms
idle
Ign on 11.6 ~ 12.0 V
11 Battery voltage Engine runs at V Battery voltage
13.5 V
idle
Ign on 0.00 %
12 Purge duty cycle Engine runs at % Percentage purge opening
0.04 %
idle
0 km/h (0
13 Vehicle speed Ign on km/h Value increases as vehicle moves
mph)
Ign on 1
Oxygen control
14 Engine runs at — Oxygen control factor
factor 0.99 ~1.01
idle
Ign on 0 ~ 900 mv
Front oxygen
15 Engine runs at mV Voltage oxygen sensor
sensor voltage 180 ~ 400
idle

FUEL 13A
DATA LIST / 165

UNIT REMARKS
NAME TION VALUE
Ign on 0 ~ 900 mv
Rear oxygen sensor
16 Engine runs at mV Voltage oxygen sensor
voltage 180 ~ 401
idle
Oxygen long term Engine runs at
17 ± 30 % Fuel adaptation
adaptation idle
Oxygen long term
Engine runs at
18 adaptation multi- ± 30 % Fuel adaptation
idle
plicative value
Oxygen long term
Engine runs at
19 adaptation fuel ± 30 % Fuel adaptation
idle
mass flow offset
50 ~ 950 °C
Catalyst temperat- Engine runs at
20 (122 ~ 1742 °C Catalyst temperature
ure model idle
°F)
Catalyst damaging Engine runs at
21 0 ~ 65535 — Misfire detection counter - cylinder 1
misfire cylinder 1 idle
25 0 ~ 65535 — —
misfire potential idle
Idle torque loss ad- Engine runs at
26 ± 30.0 Nm Torque losst adaptation
aptation value idle
Accelerator pedal
27 Ign on 0.00 % Varies when aps pressed
position
Distance since mil
28 Ign on 0 km Check fault code if value > 0km
on
Engine runs at Not active / Idle state status; active when idle
44 Idle state —
idle active switch is on
Engine runs at Not active / Load status; active when accelerator
45 Full load request —
idle active pedal at full throttle
Gear position; d hwen gear position
46 Gear position Ign on D, p/n — set to drive, p/n when gear shift to
parking/neutral
Air cond request Engine runs at Air conditioner status; on when air
47 Off / on —
signal idle cond switch to on
Engine runs at
48 Camshaft control Off / on — VVT controller status
idle
Intake manifold Engine runs at
49 Off / on — VIM controller status
control idle
Anti knock control Engine runs at
50 Off / on — Knock control status
status idle

13A FUEL
/ 166 ACTUATOR TEST

UNIT REMARKS
NAME TION VALUE
Engine runs at
51 Fuel cut off (SAS) Off / on — Fuel cut off condition
idle
Throttle body ad- Engine runs at In progress / Throttle body adaptation status; done
52 —
aptation (TBA) idle done when tba adaptation is completed
Cruise control cancel switch status;
Cruise control - Engine runs at Not active /
53 — active when cruise cancel switch is
cancel switch idle active
cancelled
Cruise control switch status; active
Cruise control set Engine runs at Not active /
54 — when cruise control switch is set to
deceleration idle active
decelerate
Cruise control switch status; active
Cruise control set Engine runs at Not active /
55 — when cruise control switch is set to
acceleration idle active
accelerate
Clutch actuated Engine runs at Not active /
56 — —
(m/t) idle active
Cruise control oper- Engine runs at Cruise control operation status; on
57 Off / on —
ation idle when auto cruise in operating mode
Target wheel ad- Engine runs at In progress /
58 — —
aptation idle done
ACTUATOR TEST WCH13ASHOOT11027
ACTUATOR TEST REFERENCE TABLE

Item Inspection Inspection Normal Inspection pro-
Drive contents
No. item contents condition cedure No.
Front Oxy- Actuate the Front Oxy-
Check status
1 gen Sensor Lambda probe Idling speed gen control- 13A/31
on PADT-II
Heater heater 1 to ON ler = ON
Rear Oxygen Actuate the Rear Oxy-
Check status
2 Sensor Heat- Lambda probe Idling speed gen control- 13A/34
on PADT-II
er heater 2 to ON ler = ON

FUEL 13A
ACTUATOR TEST / 167

Drive contents
Pinch the re-
• Ignition turn hose with
switch: ON fingers to feel
• Fuel pump Pulse is felt
the pulse of
Fuel pump oper- Forced driv- the being recir-
3 Fuel pump ates and fuel is ing Inspect culated. 13A/57
recirculated. according to
both the Listen for the
Sound of
above condi- sound of fuel
operation is
tions pump opera-
heard
tion.
Cut fuel to No. 1
4 Injector 1
injector Idling condi-
Injector 2 Cut fuel to No. 2 • Warmed up
5 tion be-
injector the Engine for Check cylin-
comes dif-
few minutes ders which af- 13A/54
Injector 3 Cut fuel to No. 3 ferent (be-
6 • Set Engine at fect idling
injector comes un-
idling speed
Injector 4 Cut fuel to No. 4 stable)
7
injector
Sound of
operation
Listen for fan
Drive the fan Ignition switch: can be
8 Fan 1 motor opera- 13A/74
motor (radiator) ON heard when
tion sound
purge valve
is driven
Sound of
operation
Drive the fan Listen for fan
Ignition switch: can be
9 Fan 2 motor motor opera- * Not fitted
ON heard when
(air conditioner) tion sound
purge valve
is driven

13A FUEL
/ 168 CHECK AT THE ENGINE-ECU

Drive contents
Throttle Po-
sition Sig-
Check status nal = X %
Throttle valve • Warmed up on PADT-II (X value in-
actuate to the Engine for crease from
Throttle
10 1. 0% few minutes 13A/37
valve 0~100%)
2. 50% • Set Engine at
3. 100% idling speed RPM goes
Listen for en- higher from
gine sound idle speed
setting
Purge Duty
Cycle = X %
Check status
(X value in-
on PADT-II
crease from
0~100%)
Purge valve
Ignition switch: Sound of
11 Purge valve turns from OFF 13A/71
ON operation
to ON Listen for
can be
purge valve
heard when
operation
solenoid
sound
valve is
driven
CHECK AT THE ENGINE-ECU WCH13ASHOOT11028
DOIMC13AR11032
TERMINAL VOLTAGE CHECK CHART

1. Connect a needle-nosed wire probe (test harness: MB991223 or paper clip) to a voltmeter probe.
2. Insert the neddle-nosed wire probe into each of the engine-ECU connector terminals from the
side, and measure the voltage while referring to the check chart.
NOTE
(1) Make the voltage measurement with the engine-ECU connected.
(2) You may find it convenient to pull out the engine-ECU to make it easier to reach connector ter-
minals.
(3) The checks can be carried out off the order given in the chart.

FUEL 13A
CHECK AT THE ENGINE-ECU / 169
CAUTION
Short-circuiting the positive (+) probe between a connector terminal and earth could damage the
vehicle wiring, the sensor, engine-ECU or all of them. Be careful to prevent this!
Symbol Description
A ECU harness
3. If voltmeter shows any division from standard value, check the corresponding sensor, actuator
and related electrical wiring, then repair or replace.
4. After repair or replacement, recheck with the voltmeter to confirm that the repair has corrected
the problem.
DOIMC13AR11031
ENGINE-ECU CONNECTOR TERMINAL ARRANGEMENT

CFE/IAFM+
ECU PIN NUMBER Check condition Normal

Check item
(Part side) (Engine condition) condition
23 Battery Voltage
Always
78 ± 12 V
Power Supply
Battery Voltage
17 Ignition switch: ON
± 12 V
31
Power Ground Ignition switch: OFF ±0V
47
62 Fuel pump relay
Condenser fan mo-
79
tor relay
Radiator fan motor
6 Battery Voltage
relay Ignition switch: ON
± 12 V
74 A/C relay
46 Starter relay
Main relay (Power
63
supply)
90 Injector – 1
91 Injector – 2 While engine is idling after having From 11-14 V ,
warmed up, suddenly depress the accel- momentarily
77 Injector – 3 erator pedal. drops slightly
92 Injector – 4

13A FUEL

Check item
Tank Purge Valve Running at 90 °C (194 °F)— 105 °C (221
61 0V—3V
°F)
• Engine: Warm, idle (radiator fan:
OFF)
Alternator G termin- 0.4-0.8 V to 0.8-
23 • Headlamp: OFF→ON
al 1.2 V
• Rear defogger switch switch:
OFF→ON
9-13 V (After sev-
Engine warning Ignition switch:
5 eral seconds have
lamp OFF→ON
elapsed)
Turn the A/C switch
0-3 V
OFF
43 A/C switch Engine: Idle speed Turn the A/C switch
Battery Voltage
OFF (A/C com-
12 V
pressor is opening)
65 Ignition switch-ST Engine: Cranking 8 V or more
Front oxygen sensor
95 Ignition switch: ON 0-3 V
heater
70 5V
Front oxygen sensor Ignition switch ON
56 410 mv ± 41 mv
When intake air
temperature is at
3.0 V ± 0.6 V
room temperature
Intake air temperat- 27 °C (80.6 °F)
ure sensor (Com- When intake air
bined map & mat temperature is 40 1.5 - 2.1 V
sensor) °C (104 °F)
When intake air
temperature is 80 0.4 -1.0 V
°C (176 °F)
37 Vacuum sensor ±5V
68 (Combined Map & Ignition switch: ON 4 V ± 0.21 V
54 Mat Sensor) ±0V
84 Ignition switch: ON ±5V
When intake air
temperature is at
3.0 V ± 0.6 V
room temperature
27 °C (80.6 °F)
Engine coolant tem-
perature sensor When engine
coolant temperat- 0.3-1.9 V
ure is 40 °C (104 °F)
When engine
coolant temperat- 0.3-0.9 V
ure is 80 °C (176 °F)
39 — ±5V
Throttle position Ignition switch: ON
72 — ±0V

FUEL 13A

Check item
Throttle valve
Throttle position 0.5 V ± 0.5 V
71 closed
sensor 1 Ignition switch: ON Throttle valve open 4.65 V ± 0.5 V
(move the throttle
valve manually) Throttle valve
Throttle position 4.5 V ± 0.5 V
87 closed
sensor 2
Throttle valve open 0.35 V ± 0.5 V
60 Engine: Cranking 0.4-3.0 V
Camshaft sensor
73 Engine: Idle speed 0.5-2.0 V
35 Engine: Cranking 0.4-4.0 V
Crankshaft sensor
36 Engine: Idle speed 1.5-2.5 V
Approximately 5
27
Pedal at all condi- V
Accelerator Pedal tion Approximately 0
12
Sensor 1 V
Pedal release 4.5 V ± 0.5 V
19
Pedal fully pressed 0.55 V ± 0.5 V
Ignition switch: ON
Approximately
11
Pedal at all condi- 2.5 V
Accelerator Pedal tion Approximately 0
20
Sensor 2 V
Pedal release 2.5 V ± 0.5 V
67
Pedal fully pressed 0.55 V ± 0.5 V
Push the main Approximately 12
24
switch V
Push the ACC set/ Approximately 12
22
Cruise Control Ignition switch Z: RESUME switch V
Switch ON Push the COAST/ Approximately 12
28
SET switch V
Push the cencel Approximately 0
81
switch V
66
Key Ring Antenna Ignition switch: ON 1.5-4.0 V
3
Approximately 0
50
V
Knock Sensor Ignition switch: ON
Approximately
34
2.5 mv ± 0.5 mv
48 Ignition Coil – 1
80 Ignition Coil – 2 Approximately
Ignition switch: ON
96 Ignition Coil – 3 0.38 V± 0.02 V
64 Ignition Coil – 4

13A FUEL

Check item
Brake pedal press ±0V
82 At all condition Brake pedal release Battery Voltage
± 12 V
Brake Light Switch
Brake pedal press Approximately
30 Ignition switch: ON 2.5 V ± 0.3 V
Brake pedal release 11~14 V
Approximately
1
1.908 V ± 0.2 V
Can Interface Ignition switch: ON
Approximately
9
3.136 V ± 0.2 V
Set selector level to
0V
P or N
42 Start lock Ignition switch: ON
Set selector lever to
12 V
other than P or N
Engine running Engine at 900 rpm 30 Hz
(Using a digital
75 Engine speed signal
multimeter, switch Engine at 3000 rpm 100 Hz
to frequency mode)
CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS WCH13ASHOOT11078
1. Turn the igniton switch to OFF.

2. Disconnect the engine-ECU connector.
3. Measure the resistance and check for continuity between the terminal of the engine-ECU harness-
side connector while referring to the check chart.
NOTE
(1) When measuring resistance and checking continuity, a harness for checking contact pin pressure
should be used instead of inserting a test probe.
(2) All the sensors must be in room temperature 27 °C (80.6 °F) and at adle position.
(3) Check need to be carried out in the order given in the chart.
CAUTION
If the terminals that should be checked are mistaken, or if connector terminal are not correctly
shorted to earth, damage may be caused to the vehicle wiring, sensors, engine-ECU and/or ohmmeter.
Be careful to prevent this!
(4) If the ohmmeter shows any deviation from the standard value, check the corresponding sensor,
actuator and related electrical wiring, and then repair or replace.
(5) After repair or replacement, recheck with the ohmmeter to confirm that the repair or replacement
has corrected the problem.

FUEL 13A
DOIMC13AR11031
Terminal No.
Inspection item Standard resistance values
(harness side)
84 – 52 Coolant temperature sensor 2.0 kΩ ± 0.6 kΩ
Intake air temperature sensor (combined
69 – 54 2.0 kΩ ± 0.6 kΩ
MAT and MAP sensor)
71 – 72 Throttle position sensor – 1 0.4 kΩ ± 2.0 kΩ
87 – 72 Throttle position sensor – 2 1.20 kΩ ± 0.24 kΩ
16 – 8 Throttle actuator Less than5 Ω
19 – 12 Accelerator pedal sensor – 1 1.1 kΩ ± 0.6 kΩ
20 – 11 Accelerator pedal sensor – 2 1.1 kΩ ± 0.6 kΩ
35 – 36 Crank sensor 650 Ω ± 130 Ω
50 – 34 Knock sensor More than1000 kΩ
95 – 63 Front oxygen sensor 4.5 Ω ± 0.5 Ω
93 – 63 Tank purge valve 26.0 Ω ± 5.2 Ω
90 – 63 Injector – 1
12.0 Ω ± 2.4 Ω
48 – 63 Ignition coil – 1
Less than1.0 Ω

13A FUEL
/ 174 ECU
ECU WCH13ASASSY11002
DOIMC13AR11109
Pre-removal and Post-installation operation

• Floor Console removal and installation (Refer to Pub. No. RDWE-08MA010, GROUP 52A — Floor
Console).
CAUTION
(1) Before remove the ECU wiring harness connectors, ensure disconnect the battery terminal first.
(2) After install the ECU, ensure connect the ECU wiring harness connectors properly.
ECU removal steps:
1. ECU wiring harness connector.
2. ECU assembly

FUEL 13A
ECU / 175
FLOOR CONSOLE REMOVAL

NOTE:
Detail service procedure for removal floor con-
sole, refer to GROUP 52A – Floor console (PUB.
NO. RDWE-08MA010).
ECU REMOVAL
CAUTION
Before remove the ECU wiring harness connect-
ors, ensure disconnect the battery terminal first.
1. Use the small screw driver push the ECU
connector lock.
DOIMC023R11175
2. Disconnect the ECU connector (small connect-

or).
DOIMC023R11176
3. Use the small screw driver push the ECU

connector lock.
DOIMC023R11183

13A FUEL
/ 176 ECU
4. Disconnect the ECU connector (big connect-

or).
DOIMC023R11184
5. Remove the ECU mounting nuts (4 pieces).
DOIMC023R11185
6. Remove the ECU from the bracket.

ECU INSTALLATION
Reverse order procedure removal to install back
the ECU.
CAUTION
After install the ECU , ensure the connectors fits
in firmly on TCU or ECU pin.
FLOOR CONSOLE INSTALLATION

DOIMC023R11186
NOTE:
Detail service procedure for install the floor
console, refer to GROUP 52A – Floor console
(PUB. NO. RDWE-08MA010).

FUEL 13A
INJECTOR / 177
INJECTOR WCH13ASASSY11001
DOIME11AR11005
— Lubricate all O-rings injector with engine oil during reassembly

: Non–reusable parts
Removal steps :
1. Fuel rail assy
2. Injector clip
3. O-ring
4. Injector
5. Throttle body
6. Throttle body seal
T1 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
INJECTOR/HIGH-PRESSURE FUEL HOSE INSTALLATION
1. Apply a drop of new engine oil to the O-ring.
CAUTION
Be sure not to let engine oil enter the delivery pipe.

13A FUEL
/ 178 INJECTOR
2. While turning the injector and high-pressure fuel hose to the right and left, install the delivery
pipe, while being careful not to damage the O-ring. After installing, check that the hose turns
smoothly.
3. If it does not turn smoothly, the O-ring may be trapped, remove the fuel rail pressure and then
reinsert it into the delivery pipe and check once again.

FUEL 13A
INJECTOR / 179
REMOVAL OF INJECTORS
1. Remove the injector clip using screw driver.
2. Pull out the injector from fuel rail. Take care
not to drop the injectors.
Symbol Description
A Injector clip
B Fuel rail
C Injector
DOINE11AR11037 D Screw driver

NO-RETURN VALVE INSTALLATION
Before install the no-return valve, ensure the
arrow direction to electronic throttle body.
Symbol Description
A No-return valve
B Arrow
DOIME11AR07014
INSTALLATION OF INJECTORS
1. Fit a new O-ring, on the injector.
Symbol Description
A O-ring
2. Coat the O-ring with spindle oil.
CAUTION :
(1) Be sure not to let spindle oil get into the
fuel rail.
(2) Beware not to insert injector slantingly.
DOIME13BR07004
3. Insert the injector top end onto the fuel rail

while turning the injector in both directions.
Make sure the injector turns smoothly.
If the injector does not turn smoothly, prob-
able cause is the O-ring which can bind in
the fuel rail.
Symbol Description
B Injector
C Fuel rail
DOINE11AR11039

13A FUEL
/ 180 INJECTOR
4. Install a new injector clip by sliding the open

end onto the fuel rail and the injector slot.
Confirm that the injector clip is in close con-
tact with the fuel rail and the injector slot.
Symbol Description
D Injector clip
E Injector slot
DOIME13BR07006

INTAKE AND EXHAUST 15
Content /1
15 INTAKE AND EXHAUST

INTAKE MANIFOLD AND VACUUM TANK ASSY ................................ 15/2
CONNECTOR AND HOSE LOCATION ............................................ 15/2
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15/2
PRE-REMOVAL SERVICE POINTS .................................................. 15/3
DISCONNECT CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15/3
REMOVAL AND INSTALLATION ................................................... 15/5
REMOVAL SERVICE POINTS ....................................................... 15/7
INSTALLATION SERVICE POINTS .................................................. 15/8
EXHAUST MANIFOLD ................................................................ 15/10

REMOVAL AND INSTALLATION .................................................. 15/10
EXHAUST PIPE AND MAIN MUFFLER .............................................. 15/17


/2 INTAKE MANIFOLD AND VACUUM TANK ASSY
INTAKE MANIFOLD AND VACUUM TANK ASSY WCH015SASSY11001
CONNECTOR AND HOSE LOCATION

DOIMC015R11001
NOTE:
(1) For removal the intake manifold, ensure disconnect the battery terminal first.
(2) Disconnect the engine harness properly before removal intake manifold.
(3) For installation, make sure install all hose connection.
Disconnection connector and hose.
A — Solenoid hose.
B — Solenoid valve harness connector.
C — Throttle body actuator harness connector.
D — Cam sensor harness connector.
E — Breather hose (Full load).
F — Crank sensor harness connector.
G — Intake engine harness connector.
H — Breather hose (Part load).
I — Injector harness connector.
J — Vacuum actuator harness connector.
K — Mass air temperature (T- Map) sensor harness connector.
L — Vacuum hose.

INTAKE MANIFOLD AND VACUUM TANK ASSY /3
PRE-REMOVAL SERVICE POINTS

WCH015SPROC11001
NEGATIVE BATTERY CABLE FROM THE

BATTERY DISCONNECTION
Disconnect the battery cable (- ve) and tape the
terminal.
CAUTION
Wait at least 5 minutes after disconnected the
battery cable before doing any further work.
Symbol Description
DOIMC015R07017
A Battery cable
B Insulating tape
C Battery
DISCONNECT CONNECTOR
Disconnect the harness connector at engine room
(Refer to 15/2 ).
HIGH-PRESSURE FUEL HOSE REMOVAL

When remove the high-pressure fuel hose (A)
from the delivery pipe (B) press the connector
and release it from the delivery pipe.
NOTE
Be careful not to damage the connector and hose
line.
Symbol Description
Quick connector type; press for-
A
ward the connector and pull
DOIMC015R07013
B Delivery pipe
CAUTION
Quick connector must be inserted securely into
the mating pipe until the retainer holds the pipe
spool. Check the connection by pulling the con-
nector gently forward to direction B as shown
in the illustration.
FUEL RAIL ASSY AND INJECTOR REMOVAL

1. Remove all the injectors connector by push
the lock pin then pull out the connector
properly as shown in the illustration.
Symbol Description
A Injector harness connector
B Lock pin
DOIMC015R11010

2. Remove fuel rail assy bolts - 2 pieces.
Symbol Description
C Fuel rail assy
D Bolt
DOIMC015R11019
3. Loose the lifting eye bolt.
Symbol Description
E Lifting eye
DOIMC015R11028
4. Remove the fuel rail assy properly as shown

Symbol Description
C Fuel rail assy
F Injector
CAUTION
Be careful not to drop the injector.
DOIMC015R11011

REMOVAL AND INSTALLATION WCH015SASSY11002
DOIMC015R11002

Non-reusable parts
• Fuel discharge prevention (GROUP 13–Fuel)
• Air cleaner removal (GROUP 15–Intake & Exhaust)
• Throttle body removal (GROUP 13–Fuel)
• Throttle body installation (GROUP 13 Fuel)
• Air cleaner installation (GROUP 15 Intake & Exhaust)
• All hoses need to be inserted properly to avoid leakage.
Removal steps
1. Injector harness connector
2. Fuel rail module
3. High-pressure fuel hose connection
4. Throttle body harness connector
5. Throttle body
6. Throttle body gasket
7. Intake manifold
8. Intake manifold gasket
9. Intake manifold bracket stay
10.Vacuum actuator
11.Sensor-mass air temperature (T-Map)
12.Vacuum tank
13.Solenoid valve

REMOVAL SERVICE POINTS WCH015SPROC11002
INTAKE AIR FUEL MODULE (IAFM) ASSY

REMOVAL
1. Remove the vacum tank assy. Refer to 15/5
.
2. Remove upper bracket intake manifold bolts
- 2 pieces.
Symbol Description
A Upper bracket bolt
B Intake manifold
DOIMC015R11015
3. Remove flange bolts - 5 pieces and nuts - 2

pieces nut intake manifold.
Symbol Description
B Intake manifold
C Flange bolt
D Nut
DOIMC015R11016
4. Remove intake manifold carefully
Symbol Description
B Intake manifold
DOIMC015R11021


WCH015SPROC11003
INTAKE AIR FUEL MODULE (IAFM) ASSY

INSTALLATION
1. Install the gasket into the intake manifold
groove as per shown in the illustration.
Symbol Description
A Gasket
B Intake manifold
C Groove
DOIGE11AR06052
2. Install the intake manifold to the cylinder

head properly.
Symbol Description
B Intake manifold
D Cylinder head
DOIMC015R11022
3. Tighten flange bolts - 5 pieces and intake

manifold nuts - 2 pieces to the specified
torque. Tighten all the flange bolts and nuts
accordingly in order the sequence numbers
Symbol Description
B Intake manifold
D Cylinder head
E Flange bolt
F Nut
Specified torque (E and F):
2.4 kgfm ± 0.1 kgfm
NOTE
Fasten all the flange bolts and nuts and check
the tightening torque value.
DOIMC015R11009

4. Tighten flange bolts - 2 pieces to the intake

manifold bracket as the following specified
torque:
Symbol Description
B Intake manifold
E Bolt flange
G Bracket
Specified torque (E):
1.0 kgfm ±0.1 kgfm
DOIMC015R11014
5. Install the vacuum tank assy. Refer to 15/5
.
FUEL RAIL ASSY AND INJECTOR

INSTALLATION
1. Insert the fuel rail assy to the cylinder head
properly.
Symbol Description
C Fuel rail assy
F Injector
CAUTION
Be careful not to drop the injector and torn
the injector’s O-ring.
DOIMC015R11011
2. Tighten the fuel rail assy bolts - 2 pieces.
Symbol Description
C Fuel rail assy
D Bolt
Specified torque (D):
0.97 kgm (9.7 Nm, 7.02 ft.lbs) ± 0.05 kgm (0.5
Nm, 0.36 ft.lbs)
DOIMC015R11019
3. Tighten the lifting eye bolt.
Symbol Description
E Lifting eye
Specified torque (E):
2.2 ~ 2.6 kgm (22 ~ 26 Nm, 15.91 ~ 18.81
ft.lbs)
4. Connect all the injectors connector properly.
DOIMC015R11028

/ 10 EXHAUST MANIFOLD
EXHAUST MANIFOLD WCH015SASSY11003
DOIMC015R11003
— Non-reusable parts
Pre-removal and post-installation operation
• Exhaust Pipe and Main Muffler removal and installation (Refer to Pub. No. RDWE-03DA010,
GROUP 15)
Removal steps
1. Heat shield
2. Oxygen sensor
3. Lifting eye
4. Catalytic converter bracket
5. Catalytic converter
6. Converter gasket
7. Exhaust manifold
8. Exhaust manifold gasket
T1 : 3.43 - 4.41 kgm (34.3 - 44.1 Nm, 24.81 - 31.9 ft.lbs)
T2 : 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)
T3 : 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
Tightening torque procedure for Exhaust manifold (T4) :

EXHAUST MANIFOLD / 11
Step Torque Bolt numbers

A 2.8 kgm (28 Nm, 20.25 ft.lbs) ± 0.2 kgm (2 Bolt no. 1 to Bolt no. 8
B Nm, 1.45 ft.lbs) (In ascending order)

REMOVE EXHAUST MANIFOLD

1. Disconnect the connector oxygen sensor.
Symbol Description
Oxygen sensor harness connect-
A
or
DOIMC015R11023
2. Remove heat shield bolts - 4 pieces.
Symbol Description
B Heat shield
C Bolt
DOIMC015R11024
3. Remove the heat shield and pull it out from

the oxygen sensor harness connector prop-
erly.
Symbol Description
Oxygen sensor harness connect-
A
or
B Heat shield
DOIMC015R11017
4. Remove catalytic converter bracket bolts - 2

pieces.
Symbol Description
C Bolt
D Catalytic converter
E Bracket
DOIMC015R11025

5. Remove catalytic converter nuts - 3 pieces.
Symbol Description
F Exhaust manifold
G Nut catalytic converter
DOIMC015R11026
6. Remove exhaust manifold nuts - 8 pieces.
Symbol Description
F Exhaust manifold
H Nut
DOIMC015R11006
7. Press down the catalytic converter hardly and

push it to the right side.
Symbol Description
F Exhaust manifold
DOIMC015R11012
8. Remove out the exhaust manifold from the

cylinder head stud properly.
Symbol Description
F Exhaust manifold
I Cylinder head stud
DOIMC015R11018


WCH015SPROC11005
EXHAUST MANIFOLD INSTALLATION

1. Insert the exhaust manifold gasket to the
cylinder head studs properly .
Symbol Description
A Gasket
B Stud
DOIMC015R11007
2. Install the exhaust manifold to the cylinder

head studs properly . Then, install the catalyt-
ic converter to exhaust manifold. Tighten
catalytic converter nuts - 3 pieces and exhaust
manifold nuts - 8 pieces by hand temporarily.
Symbol Description
A Gasket
B Stud
C Exhaust manifold
DOIMC015R11020
3. Tighten the exhaust manifold nuts accord-

ingly in order sequence number as shown in
the illustration. Then tighten the nuts to the
specified torque.
Tightening torque procedure for Exhaust
manifold (T1) :
Step Torque Bolt Numbers

2.8 kgm (28
Nm, 20.25
A ft.lbs) ± 0.2
kgm (2 Nm, Bolt no. 1 to
1.45 ft.lbs) Bolt no. 8
2.8 kgm (28 (In ascending
Nm, 20.25 order)
B ft.lbs) ± 0.2
kgm (2 Nm,
1.45 ft.lbs)
Symbol Description
C Exhaust manifold
NOTE
Fasten all the nuts and check the tightening
torque value.
DOIMC015R11013

4. Tighten catalytic converter bracket bolts - 2

pieces to the engine block and tighten it to
the specified torque value.
Specified torque (T2) :
2.2 ~ 2.6 kgfm
Symbol Description
E Catalytic converter bracket
F Bolt
DOIMC015R11005
5. Tighten catalytic converter nuts - 3 pieces to

exhaust manifold and tighten it to the spe-
cified torque value.
2.8 kgfm ±0.2 kgfm
Symbol Description
C Exhaust manifold
G Nut
DOIMC015R11004

6. Install the heat shield to exhaust manifold.

Ensure the oxygen sensor harness connector
is properly align to heat shield hole. Then
tighten it to the specified torque value.
2.2 ~ 2.6 kgfm
Symbol Description
H Heat shield
F Bolt
DOIMC015R11027

EXHAUST PIPE AND MAIN MUFFLER / 17
EXHAUST PIPE AND MAIN MUFFLER WCH015SASSY11004
DOIMC015R11008
Muffler sub assy removal steps
1. Nuts
2. Gasket
3. Main muffler
4. Hanger
Exhaust sub assy front removal steps
4. Hanger
5. Nuts
6. Gasket
7. Front exhaust pipe
Heat protector panel removal steps
8. Nuts
9. Front floor heat protector panel
T1 : 3.3 - 4.9 kgm (33 - 49 Nm, 23.87 - 35.44 ft.lbs)
T2 : 3.3 - 4.9 kgm (33 - 49 Nm, 23.87 - 35.44 ft.lbs)
T3 : 0.4 - 0.6 kgm (4 - 6 Nm, 2.89 - 4.34 ft.lbs)

/ 18 EXHAUST PIPE AND MAIN MUFFLER
NOTE

CLUTCH 21
Content /1
21 CLUTCH
CLUTCH CONTROL (5MTT200A) .................................................... 21/2
CLUTCH CONTROL .................................................................... 21/4

REMOVAL SERVICE POINT ......................................................... 21/4
INSTALLATION SERVICE POINT ................................................... 21/5
INSPECTION .......................................................................... 21/5
ON–VEHICLE SERVICE .............................................................. 21/6
CLUTCH BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21/6

21 CLUTCH
/2 CLUTCH CONTROL (5MTT200A)
CLUTCH CONTROL (5MTT200A) WCH021SASSY11001
DOIMC021R11001

CLUTCH 21
CLUTCH CONTROL (5MTT200A) /3
Symbol:
— Grease: (multipurpose grease unless there is a board or type specified)
Pre-removal operation
• Clutch fluid draining (Refer to page-021)
• Air cleaner removal (Refer to GROUP-015)
Post-installation operation
• Air Cleaner Installation (Refer to GROUP-015)
• Clutch Fluid Supplying (Refer to page-021)
• Clutch Pedal Adjustment (Refer to page-021)
Clutch master cylinder removal steps
1. Clevis pin
2. Reservoir hose
3. Clutch master cylinder
4. Clutch hose assy master cylinder,
Clutch line removal steps
4. Clutch,hose assy
5. Clip slot
Concentric slave cylinder adapter removal steps
• Transmission assembly (Refer GROUP 022, Transmission Assembly
6. Concentric slave cylinder adapter
T1 : 1.0 - 1.5 kgfm

21 CLUTCH
/4 CLUTCH CONTROL
CLUTCH CONTROL WCH021SPROC11001
REMOVAL SERVICE POINT

CLUTCH TUBE ASSEMBLY
DISCONNECTION/CONCENTRIC SLAVE CYLINDER
ADAPTER REMOVAL
1. Ensure no brake fluid filled in the brake fluid
reservoir,remove caps from one end of clutch
hose and from clutch master cylinder.Insert
the hose end into the clutch master cylinder
and confirm retainer clip engagement with
‘click’ sound . Pull out hose with minimal
force to reconfirm fitment.
Symbol Description
A Hose assy clutch
B Cylinder assy,clutch master
C Retainer clip
DOIMC021R11003
2. Fit the middle portion of the clutch hose into

the plastic clip (3rd slot from the top) existing
on the body dash panel
Symbol Description
D Brake line
E 3rd slot from top
F Clip
G Fit hose into clip slot
DOIMC021R11004

CLUTCH 21
CLUTCH CONTROL /5
3. Remove caps from other end of clutch hose

and from Csc adaptor. Insert the hose end
into csc adaptor and confirm retainer clip
engagement with ‘click’ sound .Pull out hose
with minimal force to reconfirm fitment.
Symbol Description
A Hose assy clutch
C Retainer clip
H Adaptor,Csc
CAUTION
• Do not remove the O-rings and the clips from
the clutch tube assembly, the clutch master
cylinder, the concentric slave cylinder ad-
apter and the concentric slave cylinder.
• If the O-rings or the clips of the clutch tube
assembly, the clutch master cylinder, the
concentric slave cylinder adapter and the
concentric slave cylinder are damaged, re-
place each assembly.
DOIMC021R11005

CONCENTRIC SLAVE CYLINDER
ADAPTER/CLUTCH TUBE ASSEMBLY
CONNECTION
CAUTION
• When connecting each part, check that the
O-ring and clip are not damaged.
• If any connection area or O-ring is dirty,
clean with the clutch fluid.
Assemble the clip to the clutch master cylinder,
clutch tube assembly and concentric slave cylin-
der. Then, connect concentric slave cylinder ad-
apter.
INSPECTION
• Check the clutch tube for cracks or clogging.
DOIMC021R11006

21 CLUTCH
/6 CLUTCH CONTROL
ON–VEHICLE SERVICE WCH021SPROC11002
CLUTCH BLEEDING
CAUTION
Use the specified brake fluid. Do not mix brake
fluids.
Specifield fluid : Brake fluid DOT 3 or DOT 4
1. Connect a hose with a bottle to the bleeder
screw.
2. Open the bleed nipple.
3. Depress the clutch pedal slowly. Open the
bleeder screw to let air and brake fluid out.
DOIMC021R11002 Close the bleeder screw. Release the clutch
pedal. Repeat until only brake fluid and no
air comes out.
4. Check that the brake fluid reservoir level
stays between "MAX" and "MIN" marks
throughout the clutch bleeding process.

MANUAL TRANSMISSION 22
Content /1
22 MANUAL TRANSMISSION
SPECIFICATIONS ....................................................................... 22/2
GEAR RATIO .......................................................................... 22/2
5MTT200A (1.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/2
5MTT200A (1.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/2
LUBRICANT .......................................................................... 22/2
SPECIAL TOOLS ........................................................................ 22/2

TOOLS ................................................................................. 22/2
ON-VEHICLE SERVICE ................................................................. 22/3

DIFFERENTIAL SEAL ................................................................ 22/3
DIFFERENTIAL SEAL LH/RH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/3
DIFFERENTIAL SEAL LH/RH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/4
TRANSMISSION OIL LEVEL CHECK ............................................... 22/5
TRANSMISSION OIL REPLACEMENT ............................................. 22/6
Transmission oil draining: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/6
Transmission oil refilling: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/8
TRANSMISSION CONTROL .......................................................... 22/10

TRANSMISSION ASSEMBLY ......................................................... 22/18


/2 SPECIFICATIONS
SPECIFICATIONS WCH022SPECS11001
GEAR RATIO
5MTT200A (1.3)
Model 5MTT200A (AF6C-7002–AA)
Applicable engine 1.3L NAFE
Gear ratio
1st 3.545
2nd 2.045
3rd 1.414
4th 1.108
5th 0.878
Reverse 3.615
Final gear ratio 3.8
Speedometer gear ratio 31/36
5MTT200A (1.6)
Model 5MTT200A (AF6C-7002–CA)
Applicable engine 1.6L NAFE
Gear ratio
1st 3.583
2nd 1.926
3rd 1.281
4th 0.951
5th 0.756
Reverse 3.615
Final gear ratio 3.8
Speedometer gear ratio 31/36
LUBRICANT
Items Specified lubricant Quantity
Transmission oil Castrol BOT130M WSD-M2C200-C 1.8 lit (1.89 U.S.qts, 1.56
Imp.qts)
SPECIAL TOOLS WCH022STOOL11001
TOOLS
To install differential oil

G922–17 Mounter
seal
DOIMT22DR11012

ON-VEHICLE SERVICE /3

To install drive shaft (This
tool should be used for
the prevention of differ-
EZT 0041 Oil seal protector
ential side oil seal dam-
age when installing drive
shaft to transmission)
DOIMC026R07013
Use as holder for transmis-

EZT 0003 TV Damper
sion removal
DOIGE11AR03105
To supporting the engine

GENERAL SERVICE assembly during removal
Engine lifter
TOOL MZ203827 and installation transmis-
sion assembly.
DOIIC023R9007
ON-VEHICLE SERVICE WCH022SPROC11005
DIFFERENTIAL SEAL
In case of damage/leakage on seal or half shaft.
DIFFERENTIAL SEAL LH/RH REMOVAL
1. Drain transmission oil (Detail procedure refer
to 22/6 ).
2. Remove the tyre LH/RH detail procedures
refer to GROUP 031 – Wheel and tyre (PUB.
NO. RDWE-08MA010).
3. Remove the tie rod end connection detail
procedures refer to GROUP 37A – Steering
4. Remove the lover arm ball joint connection
bolt refer to GROUP 33A – Lower Arm (PUB.
NO. RDWE-08MA010).

/4 ON-VEHICLE SERVICE
5. Insert a bar between transmission case and

the drive shaft in order to remove the drive
shaft.
DOIMC022R11036
6. Use a big screw driver to pinch out the seal.

Be careful not to put screwdriver in too deep,
otherwise the housing can be damaged by
the tip of the screwdriver.
DOIMC022R11037
DIFFERENTIAL SEAL LH/RH INSTALLATION

1. Take a new seal and put it in the transmission
housing, place the special tool G922–17on
the seal and use a hammer to knock oil seal
into the transmission housing. Hammer it all
the way in untill no further is possible.
DOIMC022R11038

2. Locate the special tool EZT 0042 at the differ-

ential seal as shown in the illustration.
DOIMC023R11042
3. Insert slowly and carefully drive shaft into

the transmission hole.
Remove the special tool EZT 0042 by pulling
slowly downward and push drive shaft com-
plete into the transmission.
NOTE
The purpose of using the special tool EZT
0042 is to prevent any damage to the oil seal
during drive shaft installation.
4. Install the lover arm ball joint connection
NO. RDWE-08MA010).
DOIMC023R11043
5. Install the tie rod end connection detail pro-
cedures refer to GROUP 37A – Steering (PUB.
NO. RDWE-08MA010).
6. Install the tyre LH/RH detail procedures refer
to GROUP 031 – Wheel and tyre (PUB. NO.
RDWE-08MA010).
7. Refill transmission oil (Detail procedure refer
to 22/6 ).
TRANSMISSION OIL LEVEL CHECK

WCH022SPROC11001
In case of an oil level check proceed as follow:

1. Lift up the vehicle.

2. Disconnect the reverse lamp switch connector

and remove the reverse lamp switch.
DOIMC022R11001
3. Oil level should be at the lower portion of

the reverse lamp switch hole (the oil level
will be at a correct level) as shown in the il-
lustration.
NOTE
If transmission oil not come out, refill trans-
mission oil (refer to 22/6 ).
4. Check that the transmission oil is not notice-
ably dirty, and that is suitable viscosity.
DOIMC022R11002
5. If level transmission oil is at the lower portion

of the reverse lamp switch hole, install the
reverse lamp switch and tighten to the spe-
cified torque.
Tightening torque:
2.0~2.5 kgm (20~25 Nm, 14.47~18.08 ft.lbs)
TRANSMISSION OIL REPLACEMENT

WCH022SPROC11004
Transmission oil draining:
DOIMC022R11007
1. Place the car on a flat ground.

2. Start the engine and let it run to warm up

the transmission.
3. Stop the engine.
4. Lift up the vehicle and remove the under
cover LH.
DOIMC032L08012
5. Remove the drain plug and then drain the

transmission oil.
DOIMC022R11004

6. If all transmission oil come out, install it drain

plug to the transmission and tighten to the
specified torque.
Tightening torque:
2.9~4.1 kgm (29~41 Nm, 20.98~29.66 ft.lbs)
DOIMC022R11003
Transmission oil refilling:

1. Remove the Air- cleaner (Refer to Pub. RD-
WE-08MA010)
2. Disconnect speedometer connector and re-
move the speedometer.
DOIMC022R11005
3. Fill new transmission oil into the speedomet-

er hole as shown in the illustration.
Specified transmission oil:
Castrol BOT130M WSD-M2C200–C
Quantity: 1.8 litre.
DOIMC022R11006

4. Disconnect the reverse lamp switch connector

and remove the reverse lamp switch.
DOIMC022R11001
5. Ensure the transmission oil come out from

reverse lamp switch hole, if transmission oil
not come out, refill transmission oil (repaid
step 2).
DOIMC022R11002
6. Install the reverse lamp switch and tighten

Tightening torque:
2.0~2.5 kgm (20~25 Nm, 14.47~18.08 ft.lbs)
DOIMC022R11007

/ 10 TRANSMISSION CONTROL
TRANSMISSION CONTROL WCH022SASSY11001
DOIMC022R11035

• Floor console removal and installation (Refer to GROUP 52A — Floor console, PUB NO RDWE-
08MA010).
• ECU bracket assembly removal and installation refer to 23/239 .
CAUTION :SRS
Be careful not to subject the SRS-ECU to any shocks during removal and installation of the shift
cable and select cable assembly

TRANSMISSION CONTROL / 11
Selector cable and shift cable assembly removal steps

1. Selector cable connection (Transmission side)
2. Clip
3. Shift cable connection (Transmission side)
4. Shift knob
5. Clip
6. Selector cable connection (Shift lever side)
7. Shift cable connection (Shift lever side)
8. Selector cable and shift cable assembly
Shift lever assembly removal steps
4. Shift knob
5. Clip
6. Selector cable connection (Shift lever side)
7. Shift cable connection (Shift lever side)
9. Shift lever assembly
T1 : 1.0~1.5 kgm (10~15 Nm, 7.23~10.85 ft.lbs)

REMOVAL SERVICE POINT WCH022SPROC11002
NOTE
Detail procedure for removal and installation of
floor console refer to the GROUP 52A-Floor
console Pub. NO. RDWE–08MA010.
CAUTION
Be careful not to subject the SRS-ECU to any
shocks during removal and installation of the
transmission control cable.
SELECTOR CABLE AND SHIFT CABLE

REMOVAL
1. Lift up the vehicle remove the front cover.
DOIMC022R11008
2. Use the plier to release the selector cable

connection from transmission selector lever.
DOIMC022R11009
3. Use the screw driver to release the selector

cable clip and remove the selector cable.
DOIMC022R11010

4. Use the plier to release the shift cable con-

nection from transmission shift lever.
DOIMC022R11011
5. Use the screw driver to release the shift cable

clip and remove the shift cable.
DOIMC022R11012
6. Release the selector cable and shift cable

from the cable support.
DOIMC022R11013
7. Use the small screw driver remove the select-

or cable clip and disconnect the selector
cable.
DOIMC022R11014

8. Use the small screw driver remove the shift

cable clip and disconnection the shift cable.
DOIMC022R11015

cable from the shift lever bracket.
DOIMC022R11016

from the shift lever bracket.
DOIMC022R11017
11. Remove the ECU bracket bolts (3 pcs).

NOTE
•Detail service procedure for removal and
install ECU bracket, refer to 23/238 .
•Push the ECU bracket to the left hand side
for easier to remove the retainer nut.
DOIMC022R11018

12. Remove the retainer nut. (2 pcs).
DOIMC022R11019
13. Remove the selector cable and shift cable

assembly.
DOIMC022R11020
SHIFT LEVER ASSEMBLY REMOVAL

1. Use the small screw driver remove the select-
or cable clip and disconnect the selector
cable.
DOIMC022R11014
2. Use the small screw driver remove the shift

cable clip and disconnection the shift cable.
DOIMC022R11015


cable from the shift lever bracket.
DOIMC022R11016

from the shift lever bracket.
DOIMC022R11017
5. Remove the shift lever nuts and remove shift

lever assembly.
DOIMC022R11039

SELECTOR CABLE AND SHIFT CABLE
INSTALLATION
selector cable and shift cable assembly.
CAUTION
After install the selector cable, shift cable as-
sembly and shift lever assembly, ensure checking
the operation of shift lever.
DOIMC022R11034

SHIFT LEVER ASSEMBLY INSTALLATION

shift lever assembly.
CAUTION
After install the selector cable, shift cable as-
sembly and shift lever assembly, ensure checking
the operation of shift lever.

/ 18 TRANSMISSION ASSEMBLY
TRANSMISSION ASSEMBLY WCH022SASSY11002
DOIMC022R11040

• Air cleaner removal and installation (Refer to Pub. No. RDWE-08MA010, GROUP 015 — Air
cleaner).
• Battery and battery tray removal.
• Selector cable and shift cable removal and installation (Refer to 22/12 ).
• Transmission oil draining (Refer to 22/6 ).
• Exhaust front removal and installation (Refer to Pub. No. RDWE-08MA010, GROUP 015 — Exhaust
front).
• Catalytic converter removal and installation (Refer to Pub. No. RDWE-08MA010, GROUP 015 —
Intake and exhaust).
• Front sub-frame removal and installation (Refer to Pub. No. RDWE-08MA010, GROUP 032 —
Front sub-frame).
• Drive shaft removal and installation (Refer to 22/3 ).
NOTE:
(1) Before remove the transmission, ensure disconnect the transmission wiring harness connectors
first.
(2) Support the radiator assy by wire.
(3) Support the power steering assembly by wire.
(4) After install the transmission, ensure connect the transmission wiring harness connectors
properly.

TRANSMISSION ASSEMBLY / 19
Removal steps:
1. Battery terminal( +/-)
2. Reverse lamp switch connector
3. Speedometer connector
4. Engine wiring harness and battery wiring harness connection connector
5. Clutch hose assy connection
6. Cable support
DOIMC022R11041
Removal steps 12. Transmission assembly lower part coupling
7. Selector cable connection bolts (5 pieces)
8. Clip 13. Starter coupling bolts (2 pieces)
9. Shift cable connection 14. Transmission assembly upper part coupling
10. Drive shaft RH bolt (3 pieces)
11. Drive shaft LH 15. Transmission mounting bracket assy
16. Transmission assembly
T1 : 10.0 kgm (100 Nm, 72.33 ft.lbs) ± 1.0 kgm (10 T4 : 3.5~4.5 kgm (35~45 Nm, 25.32~32.55 ft.lbs)
Nm, 7.23 ft.lbs) T5 : 2.8~3.2 kgm (28~32 Nm, 20.25~23.15 ft.lbs)
T2 : 5.7 kgm (57 Nm, 41.23 ft.lbs) ± 0.7 kgm (7 Nm,
5.06 ft.lbs)
T3 : 4.8~5.2 kgm (48~52 Nm, 34.72~37.61 ft.lbs)

CAUTION:
Mounting locations marked by * should be provisionally tightened and then fully tightened when
the body is supporting the full weight of the engine.

AIR-CLEANER REMOVAL
NOTE:
Detail service procedure for removal the Air-
cleaner, refer to GROUP 015 – Air-cleaner (PUB.
NO. RDWE-08MA010).
BATTERY AND BATTERY TRAY REMOVAL

NOTE:
Detail service procedure for removal the battery
and battery tray, refer to GROUP 054 (PUB. NO.
RDWE-08MA010).
FRONT SUB FRAME REMOVAL

NOTE:
Detail service procedure for removal the front
sub frame, refer to GROUP 032 – Front sub frame
TRANSMISSION ASSEMBLY REMOVAL

1. Remove the all harness clips and harness
bracket at the transmission.
DOIMC022R11021
2. Remove the reverse lamp switch harness

connector.
DOIMC022R11042

3. Remove the speedometer harness connector.
DOIMC022R11022
4. Remove the battery wiring harness and en-

gine wiring harness connector.
DOIMC022R11043
5. Disconnect the Concentric slave cylinder ad-

apter hose clip (CSC).
DOIMC022R11023
6. Remove the transmission cable support.
DOIMC022R11028

7. Lift up the vehicle, remove the under cover

LH.
DOIMC032L08012
8. Using the Allen key remove the drain plug

to drain the transmission oil.
DOIMC022R11004
9. Remove the shift control front cover.
DOIMC022R11008

10. Using the plier release the selector cable and

shift cable connection from transmission se-
lector lever (Detail procedure, refer to 22/12
).
DOIMC022R11009
11. Remove the shift control back cover.
DOIMC022R11024
12. Insert a pry bar between the transmission

case and the drive shaft in order and pry out
the drive shaft.
CAUTION
(1) Be careful do not damage the transmis-
sion case.
(2) Do not insert the pry bar too deep be-
cause it will damage the transmission oil
seal.
DOIMC022R11036

13. Hang the drive shaft with a cord for easier

to remove the transmission.
DOIMC023R11026
14. Remove the transmission lower coupling

bolts 4 pieces, 1 piece loosen only.
DOIMC022R11026
15. Lift down the vehicle.

Remove the transmission upper coupling
bolts 2 pieces, 1 piece loosen only.
DOIMC022R11027

16. Disconnect the oxygen sensor connector.
DOIMC023R11020
17. Remove the exhaust manifold heat protector.
DOIMC023R11021
18. Remove the catalytic converter upper

mounting nuts.
DOIMC023R11022
19. Lift up the vehicle and remove the catalytic

converter lower mounting bolts.
DOIMC023R11023

20. Remove the catalytic converter assembly.
DOIMC023R11024
21. Set the engine lifter MZ2033827 to the

vehicle in order to support the engine as-
sembly.
NOTE
Locate engine hanger to the new position
as shown in the illustration (to get a center
point balancing of the engine).
DOIMC023R11013
22. Remove the transmission mounting nuts and

remove the engine mounting assy.
DOIMC022R11029

23. Install the special tool EZT 0003 at the trans-

mission and remove the transmission coup-
ling bolt upper.
DOIMC022R11030
24. Remove the transmission coupling bolt lower.
DOIMC022R11044
25. Remove the transmission assembly from the

engine.
Using the garage jack, slowly lift down the
transmission assembly.
DOIMC022R11031
26. Remove the transmission from the vehicle.

CAUTION
Be careful do not drop the transmission as-
sembly.
TRANSMISSION ASSEMBLY INSTALLATION
1. Reverse order procedure removal to install
back transmission assembly.
2. Detail procedure for refilling the transmission
oil, refer to 22/6 .
DOIMC022R11032

TRANSMISSION MOUNTING STOPPER

INSTALLATION
Install the transmission mounting stopper by
ensuring the arrow is 'UP' direction as shown in
the illustration.
CAUTION:
Please ensure the transmission mounting stopper
is properly fitted and installed at it position be-
fore tightening the transmission insulator
mounting bolt.
DOIMC022R11046
FRONT SUB FRAME INSTALLATION
NOTE:
Detail service procedure for install the front sub
frame, refer to GROUP 032 – Front sub frame
BATTERY AND BATTERY TRAY

INSTALLATION
NOTE:
Detail service procedure for install the battery
and battery tray, refer to GROUP 054 (PUB. NO.
RDWE-08MA010).
AIR-CLEANER INSTALLATION
NOTE:
Detail service procedure for install the Air-
cleaner, refer to GROUP 015 – Air-cleaner (PUB.
NO. RDWE-08MA010).

NOTE

CVT 23
Content /1
23 CVT
GENERAL INFORMATION ............................................................ 23/8
OUTLINE OF CHANGES ............................................................. 23/8
SPECIFICATIONS ....................................................................... 23/8

GENERAL SPECIFICATIONS ........................................................ 23/8
CVT GEAR RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/8
SERVICE SPECIFICATION ........................................................... 23/8
CONTINUOUS VARIABLE TRANSMISSION <CVT> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/8
LUBRICANTS ......................................................................... 23/8
SPECIAL TOOLS ........................................................................ 23/9

TOOLS ................................................................................. 23/9
TROUBLESHOOTING .................................................................. 23/12

STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING ..................... 23/12
TROUBLESHOOTING GUIDE ....................................................... 23/13
GENERAL REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/13
INTERMITTENT MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/13
LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/13
NOISE PROBLEMS ................................................................... 23/13
SECONDARY GEAR SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/13
REVERSE SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/14
LOW SPEED GEAR SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/14
PRIMARY BALL BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/14
TRANSMISSION INSIDE BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/14
NOISE DUE TO WATER OR CONTAMINATED OIL INSIDE THE TRANSMISSION . . . . . . . . . 23/15
NOISE IN ‘N’ OR ‘P’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/16
SHOCK AND NO CREEP PROBLEMS ............................................. 23/16
SHOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/16
NO CREEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/17
DIAGNOSTIC FUNCTION ........................................................... 23/17
WARNING INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/17
FREEZE FRAME DATA ............................................................... 23/17
DISPLAY ITEM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/18
CLUTCH ADAPTATION PROCEDURE ............................................ 23/23
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/23
PRE-CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/23
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/23
TROUBLESHOOTING (CLUTCH ADAPTATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/28
SELF DIAGNOSIS ..................................................................... 23/29
ROAD TEST ........................................................................... 23/38
INSPECTION CHART FOR DIAGNOSIS CODE ................................... 23/40
P0710: OIL TEMPERATURE SENSOR FAULT ..................................... 23/43
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/43
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/44
P0218: HIGH OIL TEMPERATURE ................................................. 23/46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/46
P1767: CRITICAL OIL TEMPERATURE ............................................ 23/47
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/47
P2765: PRIMARY PULLEY SPEED SENSOR FAULT .............................. 23/49
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/49
P2766: PRIMARY PULLEY SPEED UNPLAUSIBLE ............................... 23/52
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/52

23 CVT
/2 Content
P0720: SECONDARY PULLEY SPEED SENSOR FAULT ......................... 23/55

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/55
P0721: SECONDARY PULLEY SPEED UNPLAUSIBLE ........................... 23/58
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/58
P0840: SECONDARY PRESSURE SENSOR FAULT ............................... 23/61
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/61
P0641: PRESSURE SENSOR SUPPLY FAULT ...................................... 23/64
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/64
P1765: SECONDARY PULLEY PRESSURE TOO LOW ........................... 23/67
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/67
P1766: SECONDARY PULLEY PRESSURE TOO HIGH .......................... 23/69
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/69
P0651: DMS AND SPEED SENSOR SUPPLY FAULT ............................. 23/71
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/71
P0706: DRIVE MODE SENSOR SINGLE LINE ERROR ........................... 23/74
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/74
P0705: DRIVE MODE SENSOR MULTIPLE LINES ERROR ...................... 23/75
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/75
P0659: HIGH SIDE SHORT CIRCUIT TO BATTERY .............................. 23/77
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/77
P0658: HIGH SIDE SHORT CIRCUIT TO GROUND OR OPEN CIRCUIT ....... 23/80
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/80
P0701: DOUBLE FAULT REQUIRING HIGH SIDE OPEN ........................ 23/83
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/83
P0882: BATTERY OR HIGH SIDE VOLTAGE TOO LOW ........................ 23/84
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/84
P0883: BATTERY OR HIGH SIDE VOLTAGE TOO HIGH ....................... 23/88
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/88
P0702: WATCHDOG TEST FAILED (DURING INITIALIZATION) ............... 23/92
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/92
P0962: EDS1 (PRIMARY PULLEY) SHORT CIRCUIT TO GROUND ............ 23/93
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/93
P0963: EDS1 (PRIMARY PULLEY) SHORT CIRCUIT TO BATTERY ............ 23/96
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/96
P0960: EDS1 (PRIMARY PULLEY) OPEN CIRCUIT .............................. 23/99
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/99
P0966: EDS2 (SECONDARY PULLEY) SHORT CIRCUIT TO GROUND ........ 23/102
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/102
P0967: EDS2 (SECONDARY PULLEY) SHORT CIRCUIT TO BATTERY ........ 23/105
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/105
P0964: EDS2 (SECONDARY PULLEY) OPEN CIRCUIT .......................... 23/108

CVT 23
Content /3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/108
P0902: EDS3 (CLUTCH) SHORT CIRCUIT TO GROUND ........................ 23/111
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/111
P0903: EDS3 (CLUTCH) SHORT CIRCUIT TO BATTERY ........................ 23/114
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/114
P0900: EDS3 (CLUTCH) OPEN CIRCUIT .......................................... 23/117
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/117
P1761: EDS CURRENT FAULT ...................................................... 23/119
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/119
P1762: CURRENT STUCK ........................................................... 23/121
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/121
P0930: SHIFT LOCK SHORT CIRCUIT TO GROUND ............................ 23/124
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/124
P0931: SHIFT LOCK SHORT CIRCUIT TO BATTERY OR OPEN CIRCUIT ..... 23/127
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/127
P1768: BACKLIGHT SHORT CIRCUIT TO GROUND ............................ 23/132
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/132
P1769: BACKLIGHT SHORT CIRCUIT TO BATTERY OR OPEN CIRCUIT ..... 23/134
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/134
P0868: OPERATION READINESS TIME OUT ..................................... 23/137
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/137
P0811: CLUTCH (FORWARD OR REVERSE) SLIPPING ......................... 23/138
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/138
P2787: CLUTCH TEMPERATURE TOO HIGH .................................... 23/139
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/139
P0730: RATIO CONTROL FAULT .................................................. 23/140
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/140
P1770: ENGINE SPEED TOO LOW ................................................ 23/143
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/143
P0727: HARDWIRED ENGINE SPEED UNPLAUSIBLE .......................... 23/144
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/144
P0219: POWERTRAIN SPEED OUT OF RANGE ................................. 23/146
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/146
P0944: INSUFFICIENT CLAMPING FORCE (VSM) ............................... 23/146
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/146
P1772: AT MODE SIGNAL ERROR ................................................ 23/149
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/149
P080A: EOL CLUTCH ADAPTATION NOT FINISHED ........................... 23/152
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/152
P1774: END OF LINE (EOL) CLUTCH ADAPTATION ERROR .................. 23/152
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/152

23 CVT
/4 Content

P0571: BRAKE SIGNAL ERROR .................................................... 23/154
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/154
U0301: VEHICLE CONFIGURATION MISMATCH ................................ 23/156
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/156
U0415: ABS FUNCTION ERROR ................................................... 23/158
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/158
U0001: CAN BUS OFF ............................................................... 23/162
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/162
U0121: CAN ABS COMMUNICATION FAILED .................................. 23/165
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/165
U0100: CAN ECU COMMUNICATION FAILED .................................. 23/166
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/166
U1012: CAN ENGINE SPEED SIGNAL ERROR ................................... 23/167
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/167
U1013: CAN ACCELERATOR PEDAL SIGNAL ERROR .......................... 23/167
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/167
U1014: CAN ENGINE TORQUE SIGNAL ERROR ................................ 23/168
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/168
U1016: CAN WHEEL SPEED ERROR — FRONT LEFT ........................... 23/169
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/169
U1017: CAN WHEEL SPEED ERROR — FRONT RIGHT ........................ 23/173
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/173
U1018: CAN WHEEL SPEED ERROR — REAR LEFT ............................ 23/177
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/177
U1019: CAN WHEEL SPEED ERROR — REAR RIGHT .......................... 23/181
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/181
TROUBLE SYMPTOM ................................................................. 23/184

TROUBLE SYMPTOM CHART ...................................................... 23/184
SYMPTOM PROCEDURES ............................................................ 23/185

Inspection Procedure 1: Communication with the PADT-II is not Possible 23/185
(CVT-TCU cannot be turned ON). ................................................
DIAGNOSIS PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/186
Inspection Procedure 2: Vehicle Creeps in the N Range. .................... 23/187
Inspection Procedure 3: Shock is experienced during N to D and/or N to 23/187
R shifting operation. ...............................................................
Inspection Procedure 4: Poor Acceleration or Incomplete Shifting Opera- 23/188
tion ....................................................................................
Inspection Procedure 5: Gears cannot be Changed in SAT Mode. ........ 23/190
DATA LIST ............................................................................... 23/191

CVT 23
Content /5
DATA LIST REFERENCE TABLE ..................................................... 23/191

DATA LIST REFERENCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/191
CHECK AT CVT TCU TERMINALS ................................................... 23/195

TERMINAL VOLTAGE ............................................................... 23/195
TERMINAL VOLTAGE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/195
CHECK AT CVT CONNECTOR ........................................................ 23/198

TERMINAL ARRANGEMENT ....................................................... 23/198
TERMINAL ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/198
DRIVE MODE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/200
ON-VEHICLE SERVICE ................................................................. 23/201

CVT COMPONENT LOCATION .................................................... 23/201
VIEW LOCATION .................................................................... 23/202
SHIFT CABLE ADJUSTMENT ....................................................... 23/203
INSPECTION PROCEDURES ........................................................ 23/205
CVT FLUID REFILL / CHECK ........................................................ 23/206
CVT FLUID REPLACEMENT ........................................................ 23/210
OIL LEVEL CHECK ................................................................... 23/211
DIFFERENTIAL SEAL ................................................................ 23/214
DIFFERENTIAL SEAL LH/RH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/214
DIFFERENTIAL SEAL LH/RH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/215
PRIMARY COVER .................................................................... 23/216
PRIMARY COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/216
PRIMARY COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/218
SECONDARY COVER ................................................................ 23/219
SECONDARY COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/219
SECONDARY COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/220
OIL PUMP ............................................................................. 23/220
OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/221
OIL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/222
PRIMARY BALL BEARING .......................................................... 23/223
OIL PAN AND OIL FILTER .......................................................... 23/225
DRIVE MODE SENSOR .............................................................. 23/228
HYDRAULIC UNIT ................................................................... 23/230
SECONDARY SPEED SENSOR AND BRACKET .................................. 23/232
PRIMARY SPEED SENSOR .......................................................... 23/234
MAIN CONNECTOR AND INTERNAL CABLE HARNESS ....................... 23/235
TCU, ECU AND BRACKET ............................................................ 23/238

CVT FLUID COOLER .................................................................. 23/243

TRANSMISSION CONTROL .......................................................... 23/247

SELECTOR LEVER ASSY ............................................................. 23/249
DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/249

23 CVT
/6 Content
TRANSMISSION ASSEMBLY ........................................................ 23/255


CVT 23
Content /7
NOTE

23 CVT
GENERAL INFORMATION WCH023GINFO11001
OUTLINE OF CHANGES
Due to the introduction of PUNCH Continuously Variable Transmission (CVT) , the troubleshooting
and service procedure for the transmission system has been updated.
GENERAL SPECIFICATIONS
Items Specification
Transmission Model PUNCH CVT
Transmission type CVT 2
Torque converter type 3–element with torque converter clutch
Applicable engine S4PE and S4PH
CVT GEAR RATIO
1.3 IAFM 1.6 IAFM
Gear
Min Max Min Max
CVT 0.43 2.43 0.43 2.43
SAT-1 2.41 2.41
SAT-2 1.62 1.20
SAT-3 0.97 0.85
SAT-4 0.75 0.71
SAT-5 0.59 0.57
SAT-6 0.46 0.46
Reverse 2.68
Final Drive 5.76
SERVICE SPECIFICATION
CONTINUOUS VARIABLE TRANSMISSION <CVT>
Items Standard value
Oil temperature sensor Ω at 20 °C (68 °F) Approximately 942 Ω
at 40 °C (104 °F) Approximately1121 Ω
Primary speed sensor MΩ Approximately 24.3 MΩ
Secondary speed sensor MΩ Approximately 24.3 MΩ
Oil pressure sensor kΩ Approximately 44.3 kΩ
Clutch pressure regulator Ω Approximately 5.2 Ω
Primary pressure regulator Ω Approximately 5.2 Ω
Secondary pressure regulator Ω Approximately 5.2 Ω
LUBRICANTS
Items Specified lubrican Quantity
CVT fluid ESSO EZL799 Approximately 4.15 lit (4.37 U.S.qts, 3.6 Imp.qts)
±0.05 lit (0.053 U.S.qts, 0.043 Imp.qts)

CVT 23
SPECIAL TOOLS /9
TOOLS
To install oil seal differen-

P480143 Stamp
tial
DOIIT23CR09010
P480142 Centering pin To install hydraulic unit
DOIIT23CR09009
P480037 Stamp To install primary bearing
DOIIT23CR09004
MD998350 Stamp To install primary bearing
DOINT23CR11032
To remove primary bear-

MD998348 Puller assembly
ing
DOINT23CR11030
To remove primary bear-

MB991202 Support
ing
DOIMT22DR10152

23 CVT
/ 10 SPECIAL TOOLS

EZT0041 Oil seal protector
DOIMC026R07013
To supporting the engine

GENERAL SERVICE assembly during removal
Engine lifter
TOOL MZ203827 and installation transmis-
sion assembly.
DOIIC023R9007
EZT 0047
For vehicle diagnosis
interface (VCI)
DOIMC35BR11039

and user documenta-
tion CD
DOIMC35BR11042
DLC cable(16-pin OBD Main diagnosis cable to

connector; 1 m) VCI
DOIMC35BR11041

USB cable 1.8 m
PC and VCI
DOIMC35BR11046

DOIMC35BR11045

CVT 23
SPECIAL TOOLS / 11

Ethernet cable
ing to VCI
DOIMC35BR11040

Cable keeper
cable messy
DOIMC35BR11043
Plug adapter for power To be use with power

supply supply (EZT 0050)
DOIMC35BR11044
Bag to carry set of PADT-

VCI Strorage case
II
DOIMC35BR11047

23 CVT
TROUBLESHOOTING WCH023TSHOT11029
STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
DOIMC023R11072

CVT 23
TROUBLESHOOTING GUIDE WCH023TSHOT11033
GENERAL REMARKS
Whenever there is an error detected by the transmission control unit (CVT-TCU), CVT warning indicator
lamp will be activated or flashing. When reading out the errors using PADT-II and a fault code is
found, first check if the fault code is a sporadic fault, which is the fault code do not occur in the last
driving cycle (Should be indicated with an “H“ from History). If so, just delete the fault code and check
if it does not come back. If it is not a sporadic fault, but currently active error (Should be indicated
with a “C“ from Currently), follow the action steps described below for each fault code.
Always check if the latest software is present. If not flash to the latest TCU software and check the
fault codes again.
Whenever there is a fault code or a problem with the transmission there are three basic actions to
perform first:
1. Check oil type.
2. Check oil level.
3. Redo clutch adaptation.
INTERMITTENT MALFUNCTION
The system is OK at this time. Check the fit of the pins in all connectors affected by the fault code.
LEAKS
No Fault Action
1. Ensure oil pan bolts are correctly tightened
2. Replace oil pan gasket
1 Leak from gearbox oil pan gasket
3. Replace drain plug
4. Replace oil pan complete
1. Ensure plug is correctly tightened
2 Leak from gearbox drain plug 2. Replace drain plug
3. Replace oil pan complete
1. Ensure primary cover is correctly tightened
3 Leak from primary cover 2. Replace ‘O’ ring
3. Replace primary cover
1. Ensure secondary cover is correctly tightened
4 Leak from secondary cover 2. Replace ‘O’ ring
3. Replace secondary cover complete
5 Leak from selector shaft lever Replace selector shaft lever seal
6 Leak from input shaft Replace input shaft seal
7 Leak from differential oil seal(s) Replace differential oil seals
1. Ensure pipes are correctly tightened
Leak from oil cooler pipe connec-
8 2. Replace pipes to oil cooler connection sealing rings
tions
3. Replace pipes
NOISE PROBLEMS WCH023TSHOT11034
SECONDARY GEAR SOUND

Sound description:
Sound best heared with a vehicle speed between 60 km/h (37.28 mph) to 90 km/h (55.92 mph) while
slowly accelerating. When releasing the gas pedal, sound normally is getting slower, give throttle
again, the sound comes back. The sound is like a whistle sound. The frequency of the sound goes up
with the vehicle speed. This is a normal sound from transmission which comes from the secondary
gear running into the pinion shaft gear.

23 CVT
REVERSE SOUND
Sound description:
When standing still and shift to ‘R’, a small whistle sound can be heared. When releasing brake and
start driving in ‘R’, the sound gets bigger and turns into a whining sound. This is a normal sound from
the planetary gear set inside the transmission.
LOW SPEED GEAR SOUND
Sound description:
When the vehicle speed is around 40 km/h (24.85 mph), the gas pedal is released while car is slowing
down and a whistle sound can be heared. This whistle sound is much lower in frequency than secondary
gear sound and much more difficult to hear. This is a normal sound from the pinion and crown wheel.
PRIMARY BALL BEARING NOISE
Sound description:
During driving in ‘D’ at low speed, the car makes a noise like “wengweng” noise. The frequency and
volume of the noise goes up with engine speed and not with vehicle speed.
How to check and repair:
Condition 1:
1 - Drive in ‘D’ at a constant speed around 60 km/h (37.28 mph).
2 - Shift to ‘SAT’ (Stepped AT) mode and the engine speed will goes up about 500 rpm within 1 or 2
seconds while keeping the same vehicle speed.
3 - If the sound also goes up (it goes up with engine speed and not with vehicle speed), then there
is a big chance the primary ball bearing is damaged.
4 - Replace primary ball bearing according to 23/223 .
Condition 2:
1 - Drive in ‘SAT’ mode (4th gear) at a constant speed around 60 km/h (37.28 mph).
2 - Shift to 3rd gear while keeping the same vehicle speed and the engine speed will goes up around
800 rpm.
3 - If the sound also goes up (it goes up with engine speed and not with vehicle speed), then there
is a big chance that the primary ball bearing is damaged.
4 - Replace primary ball bearing according to 23/223 .
TRANSMISSION INSIDE BEARING NOISE
Sound description:
During driving in ‘D’ at low speed, the car makes a noise like a “wengweng” noise.
1. According to the primary ball bearing noise, if the frequency and volume of the noise does not
relate with engine speed but relate to vehicle speed, then the noise could come from transmission
inside the bearings.
2. This cannot be repaired and complete transmission needs to be replace.
NOTE
Noise problems are very hard to evaluate. So before decide to replace a part of transmission or change
the complete transmission, be sure that the noise is actually coming from the transmission. Check or
replace other parts of the car which are easier to replace first.
Use the following chart to locate the origin of the noise:

CVT 23
DOIMC023R11123
NOISE DUE TO WATER OR CONTAMINATED OIL INSIDE THE TRANSMISSION

Sound description:
1. Brake the car and shift to ‘D’ or ‘R’.
2. After you release the brake, a ‘gegege’ sound can be heared. This can be heared as soon as the
car is moving.
3. While giving a throttle to accelerate (from creeping speed about 10 km/h (6.21 mph)), a ‘zhi~’
sound can be hear between speed 10 km/h (6.21 mph) to 40 km/h (24.85 mph).
NOTE
In the early stage of water contamination, it is possible you only hear the ‘gegege’ sound and not
the ‘zhi~’ sound. Some cars can also have a shock when taking off, depends on the level of con-
tamination.
1. Drain transmission oil (Refer to page 23/210 ) and remove oil pan (Refer to page 23/225 ) as well as
the primary cover (Refer to page 23/216 ).
2. If inside the primary cover and oil pan shows white stuff, then it is clear that the transmission has
been contaminated with water or other liquid.
3. Drain the transmission oil as much as possible and discard the oil filter (Refer to page 23/225 ).
4. Place new oil filter and refill the transmission oil according to 23/211 , 23/210 and 23/206 .
5. Drive the car for about 5 minutes at different speeds and accelerations.
6. Repeat step 3 to step 5 (except place new oil filter) for 2 or 3 times until the noise disappears. The
‘gegege’ sound should be disappear as well as the ‘zhi~’ sound.
7. The ‘zhi~’ sound can disappear by heating up the clutch by doing stall test:
Shift to ‘D’ and apply throttle.

23 CVT
NOTE
While doing the stall test, a fault code P2787 (clutch temperature too high) will be appeared. This
is just a self protection of the transmission against over-heating of the clutch. The fault code will
disappear automatically and you can perform the stall test again until the ‘zhi~’ sound getting
slower or disappear.
8. If the contamination was too big you will not be able to remove the sound and shocks. In that
case the transmission needs to be replaced.
NOISE IN ‘N’ OR ‘P’
1. Find out if the noise comes from engine or transmission side. If engine side, check parts related
to engine. If transmission side, the only part you can check is the pump.
2. Replace pump to check if the noise is gone. (Refer to page 23/220 )
3. If noise does not disappear by replacing the pump, then either input shaft needle bearing or
planetary gear set can be the source of noise. In this case the transmission needs to be replaced.
NOTE
Noise problems are very hard to evaluate. So before decide to replace a part of transmission or change
the complete transmission, be sure that the noise is actually coming from the transmission. Check or
replace other parts of the car which are easier to replace first.
Use following chart to locate the origin of the noise:
DOIMC023R11122
SHOCK AND NO CREEP PROBLEMS WCH023TSHOT11035
SHOCKS
Problem description:

CVT 23
During driving in D, the small vibrations or shocks can be felt.

Check and repair:
There could be many possibilities for this problem:
No Problem Solution
1 Clutch adaptation not fully finished Refer to page 23/23 .
2 Water or contaminated oil inside Refer to page 23/13 .
the transmission
3 Primary speed sensor problem Replace by refer to page 23/234 .
4 Hydraulic unit problem Replace by refer to page 23/230 and 23/23 (redo clutch ad-
aptation procedure).
5 Secondary speed sensor problem Replace by refer to page 23/232 .
NO CREEP
Problem description:
During shift to D and release the brake, the car does not move. After give throttle, the car start
moving with or without shock from about 2000 rpm.
Check and repair:
No Problem Solution
1 Fault code active Refer to page 23/13 .
2 If problem happens in cold condition Refer to page 23/23 .
3 Brake signal problem If brake is not applied but brake signal is activ-
ated, check brake switch and car cable harness.
4 Hydraulic unit problem Replace by refer to page 23/230 and 23/23 (redo
clutch adaptation procedure).
DIAGNOSTIC FUNCTION WCH023TSHOT11027
WARNING INDICATOR
When any malfunction occurs in the items related
to the CVT systems which are described below,
the symbol (A) continues being displayed at
meter combination. Check if the diagnosis code
is set when the symbol (A) continues being dis-
played using PADT-II.
Symbol Description
A CVT warning indicator
DOIMC023R11099
FREEZE FRAME DATA WCH023TSHOT11028
When the CVT-TCU detects a malfunction and stores a diagnosis code, it also stores a current status
of the transmission. This function is called "Freeze frame data". By analyzing this "Freeze frame data"
with the PADT.-II, an effective troubleshooting can be performed.
The display items of freeze frame data are shown below.

23 CVT
DISPLAY ITEM LIST

No PADT-II display Unit / Display Remark
1 Brake status OFF/ON
2 Brake fault OK/FAIL -
3 Shift lock OFF/ON
Temperature value
5 ABS signal fault (bit no: error 0: ABS activation

flag) 1: ABS braking
2: Anti slip loop controller (ASR)
active
3: Electronic Differential Cut/Lock
(EDS) active
4: Electronic Stability Program (ESP)
active
9: Brake pedal stroke
10: Quality flag brake pedal stroke
11: Mileage (km)
12: Brake light
13: Quality flag brake light
14: Handbrake Signal from ABS sys-
15: Quality flag handbrake tem when the diagnos-
16: Brake pressure is code is generated
17: Quality flag brake pressure
18: Wheel speed front left
19: Wheel speed front right
20: Wheel speed rear left
21: Wheel speed rear right
22: Quality flag wheel speed front
left
23: Quality flag wheel speed front
right
25: Quality flag wheel speed rear
left
26: Quality flag wheel speed rear
right
6 Missing ABS message(s) — Integer value

CVT 23

7 EMS signal fault (bit no: error 0: Engine torque
flag) 1: Driver demanded engine torque
2: Engine torque loss
3: Quality flag engine torque
4: Quality flag driver demanded
engine torque
5: Quality flag engine torque loss
6: Engine speed
7: Quality flag engine speed
8: Throttle
9: Acceleration pedal
10: Quality flag acceleration pedal
11: Mileage (km)
12: Brake light Signal from EMS sys-
tem when the diagnos-
13: Quality flag brake light is code is generated
14: Handbrake
15: Quality flag handbrake
16: Maximum engine torque
17: Torque reduction confirmation
18: Target wheel torque
20: Engine adaptation
21: Engine temperature
22: Quality flag engine temperature
23: Cruise control speed
26: Environmental pressure
28: Quality flag environmental
pressure
29: Engine idle target speed
8 Active error reactions (1/2) — Integer value
9 Active error reactions (2/2) — Integer value
10 Commanded current for pres- mA
Current value
sure regulator of pulley 1
Current value
sure regulator of pulley 2
Current value
sure regulator of clutch
13 Target ratio — Decimal value
14 Ratio gradient — Ratio gradient value
15 Engine torque (corrected) Nm Torque value
16 Actual current pressure regu- mA
Current value
lator pulley 1
Current value
lator pulley 2

23 CVT

Current value
lator clutch
19 Commanded clutch pressure bar
Pressure value
20 Commanded pulley 2 pressure bar

Pressure value
21 Measured pulley 2 pressure bar Pressure value

22 Position sensor -single line 0: line A short to ground
status (bit no: error flag) 1: line A short to battery
2: line A open load
3: line A plausibility
4: line B short to ground
5: line B short to battery
6: line B open load Signal from position
7: line B plausibility sensor when the dia-
8: line C short to ground gnosis code is gener-
9: line C short to battery ated
10: line C open load
11: line C plausibility
12: line D short to ground
13: line D short to battery
14: line D open load
15: line D plausibility
23 ZF reset counter — Integer value
24 SV reset counter — Integer value
25 TRAP reset counter — Integer value
26 TSK reset counter — Integer value
27 Hotmode diagnosis status (bit 0: High transmission temperature
no: error flag ) 1: Request to activate engine fan
4: Transmission ratio control - limit- Hotmode diagnosis
ing maximum engine speed status when the dia-
5: Switch off tip function gnosis code is gener-
6: Request engine torque reduction ated
7: Transmission ratio control - limit-
ing minimum engine speed

CVT 23

28 Sensor signals status (bit no: 0: Primary pulley speed substituted
error flag ) 1: Primary pulley speed temporary
undefined
2: Primary pulley speed undefined
undefined
3: Secondary pulley speed substi-
tuted
4: Secondary pulley speed tempor-
ary undefined
5: Secondary pulley speed un-
defined
6: Secondary pressure substituted Sensor signal status
7: Secondary pressure temporary when the diagnosis
undefined code is generated
8: Secondary pressure undefined
9: Lever position substituted
10: Lever position temporary un-
defined
11: Lever position undefined
12: Transmission oil temperature
substituted
temporary undefined
undefined
29 Vehicle speed based on out- km/h
Speed value
put speed
30 High side voltage V Voltage value
31 Ignition voltage V Voltage value
32 Sensor supply voltage 5V V Voltage value
33 Sensor supply voltage 8.4V V Voltage value
34 Mileage km Mileage value
35 Battery voltage V Voltage value
36 External WTD reset counter — Integer value
37 Internal WTD reset counter — Integer value
38 Lever position for freeze 0: Undefined / error
frame (bit no: status) 1: Position L
4: Position D Gear lever position
when the diagnosis
5: Position N code is generated
6: Position R
7: Position P

23 CVT

39 Clutch status (bit no: status) 0: Undefined
1: Open
2: Filling
3: Applied
4: Creeping
5: Take off Clutch status when the
diagnosis code is gen-
6: Closed erated
7: Roll out
8: Opening
9: Opening SW
10: Opening ABS
11: Opening blocking wheels (BLR)
40 Expected clutch pressure bar Pressure value
41 Engine speed rpm Engine speed value
42 Vehicle speed calculated by km/h
Speed value
TCU
43 Throttle position % Integer value
44 Pulley 1 speed rpm Pulley 1 speed value
45 Output speed rpm Output speed value
46 Clutch slip rpm Only positive value is
used
47 PWM duty cycle for EDS1 %
Integer value
(pulley 1)
Integer value
(pulley 2)
Integer value
(clutch)
50 Transmission oil temperature °C
Temperature value
51 Gear ratio — Ratio value

52 Lever position (bit no: status) 0: Unknown
1h: First Manual Gear
2h: Second Manual Gear
3h: Third Manual Gear
4h: Fourth Manual Gear
5h: Fifth Manual Gear
6h: Sixth Manual Gear Gear lever position
10h: R (reverse) when the diagnosis
20h: Z1 code is generated
21h: Z2
22h: Z3
23h: Z4
41h: SAT; First Gear
42h: SAT; Second Gear
43h: SAT;Third Gear

CVT 23

53 EOL Clutch Adaptation Error 0: No Error
1: Unstable Engine torque
Status of clutch adapt-
2: Air-cond ON
ation EOL when the
4: Pressure too high
diagnosis code is gen-
8: Engine speed too low
erated
16: Engine speed too high
32: Too many abortions
54 Engine torque (CAN) Nm Torque value
55 Last mileage counter after km
Integer value
engine off
56 Status of clutch adaption EOL 00b : Adaption values of Clutch
(value: status) forward - reverse Not finished
01b : Only Adaption values of Clutch Status of clutch adapt-
forward finished ation EOL when the
10b : Only Adaption values of Clutch diagnosis code is gen-
reverse finished erated
11b: Adaption values of Clutch for-
ward - reverse finished
CLUTCH ADAPTATION PROCEDURE WCH023TSHOT11005
INTRODUCTION
After uploading new software in the CVT-TCU, replacement of CVT-TCU or replacement of transmission,
each Transmission Control Unit (TCU) has to be adapted to the transmission after installation and
prior to first use in order to compensate for tolerances.
This is done by executing engagement actions during idle. Once this procedure is completed, lifetime
adaptation occurs automatically.
PRE-CONDITIONS
These pre-conditions need to be met before starting the clutch adaptation procedure:
1. Stable engine torque and engine rotations per minute (rpm) in idle state are required.
No Pre-condition ECU target value

1 Engine idle rpm maximum ± 100 rpm
variation in P or N
2 Engine idle torque maximum ± 0.4 kgm (4 Nm, 2.89 ft.lbs)
variation in P or N
2. Engine temperature at least 60 °C (140 °F)
3. The transmission oil temperature needs to be between 30 °C (86 °F) and 80 °C (176 °F).
4. Switch off the air-conditioning.
5. A not adapted CVT-TCU will always request an idle speed lift up till 1150 rpm from the engine.
6. In case the CVT-TCU was adapted before (service), the clutch adaptation values in the CVT-TCU
needs to be reset first using PADT-II.
PROCEDURE
1. Before starting the EOL clutch adaptation, the adaptation values in the TCU have to be reset first.
2. When all pre-conditions are fulfilled, the next actions have to be performed:
• Vehicle speed = 0 km/h (0 mph).
• Throttle pedal not applied.
• Foot brake has to be applied all the time.
• Gear lever in “Drive” position.

23 CVT
3. The EOL clutch adaptation procedure will start automatically.

4. When something disturbs the clutch adaptation, fault code P1774 will be triggered and the CVT
warning lamp will constant activated.
DOIMC023R11099
Symbol Description
A CVT warning lamp
5. As long as the clutch adaptation is not completed, fault code P080A is active and the CVT warning
lamp is blinking.
6. When everything goes smooth, the time needed to complete the adaptation in this gear is about
40 seconds. When the adaptation in this gear is not finished within 120 seconds, the procedure
has to be aborted.
7. When the clutch adaptation in this gear is completed, the engine will rev up to 1500 rpm for a
short time. It is an indicator that the next step can be started.

CVT 23
DOIMC023R11271
NOTE
Perform high speed test on dynamometer can be ignored for the After Sales market.
8. Please check again if the pre-conditions are fulfilled.

23 CVT
9. Perform the next actions:

• Vehicle speed = 0 km/h (0 mph).
• Throttle pedal not applied.
• Foot brake has to be applied all the time.
• Gear lever in “Reverse” position.
10. The EOL clutch adaptation procedure will start automatically.
11. When something disturbs the clutch adaptation, fault code P1774 will be triggered and the CVT
warning lamp will constant activated.
DOIMC023R11099
Symbol Description
A CVT warning lamp
12. As long as the clutch adaptation is not completed, fault code P080A is active and the CVT warning
lamp is blinking.
13. When everything goes smooth, the time needed to complete the adaptation in this gear is about
40 seconds. When the adaptation in this gear is not finished within 120 seconds, the procedure
has to be aborted.
14. When the clutch adaptation finishes successfully, the engine will rev up to 1500 rpm for a short
time then the engine speed drops to idle speed (850 rpm) and the CVT warning lamp will extinguish.

CVT 23
DOIMC023R11272

23 CVT
NOTE
The sequence of first adaptation in “Drive” and then in “Reverse”is not mandatory. It is also permitted
first to perform the adaptation in “Reverse” and then in “Drive”.
TROUBLESHOOTING (CLUTCH ADAPTATION)
The troubleshooting is partly being done through fault code P1774. There are 6 possibilities for raising
fault code P1774. These possible sources are bit coded into the signal EOL Clutch Adaptation Error in
the freeze frame of P1774.
EOL Clutch Adaptation Error Value Type of fault

1 Unstable engine torque
2 Air-conditioning is switched on
4 Pressure too high
8 Engine speed too low
16 Engine speed too high
32 Too many abortions
Problem Possible Cause Action
Transmission oil temperature is 1. Allow the transmission to heat
below 30 °C (86 °F) during adapta- up (engine on).
tion process. 2. Restart adaptation procedure.
Transmission oil temperature ex- 1. Allow the transmission to cool
Test procedure has to be ceeds 80 °C (176 °F) during adapt- down (engine off).
aborted after 120 seconds ation process. 2. Restart adaptation procedure.
without the clutch adaptation 1. Allow engine to heat up (en-
bit being set. Engine temperature is below 60
gine on).
°C (140 °F).
2. Restart adaptation procedure.
Foot brake has been released for 1. Make sure that foot brake is
a short while during adaptation always applied.
process. 2. Restart adaptation procedure.
1. Improve engine torque stabil-
P1774: EOL clutch adaptation Unstable engine torque during ity. Make sure engine adapta-
error = 1 adaptation process. tion is completed successfully.
1. Switch off the air-conditioning
P1774: EOL clutch adaptation during complete adaptation
Air conditioning is switched on.
error = 2 process.
1. Check if transmission can
transmit torque when gear
Clutch pressure is increase which lever is put into D or R.
P1774: EOL clutch adaptation makes transmission load to the 2. Check if engine torque signal
error = 4 engine, but the engine torque is OK.
signal does not increase. 3. Make sure engine adaptation
is completed successfully.
1. Improve engine rpm stability.
P1774: EOL clutch adaptation Engine speed is too low during 2. Make sure engine adaptation
error = 8 adaptation process. is completed successfully.

CVT 23
Problem Possible Cause Action

1. Improve engine rpm stability.
P1774: EOL clutch adaptation Engine speed is too high during 2. Make sure engine adaptation
error = 16 adaptation process. is completed successfully.
The adaptation process is some-
times interrupted caused by a 1. Make sure that all the auxiliar-
sudden engine torque change ies are not switched on/off
P1774: EOL clutch adaptation
which can be caused by auxiliaries during the complete adapta-
error = 32
(turned on or off). E.g: Fan, steer, tion process.
window opening/closing, heating, 2. Restart adaptation procedure.
etc.
SELF DIAGNOSIS WCH023TSHOT11001
NOTE
No Item Description
1 High side Supply voltage for the three pressure regulators. When error code occurs
and high side is switched off, then the clutch goes open and the vehicle
cannot move anymore until you do a KEY ON/OFF.
2 Increased clamping Secondary pressure is at a fixed level, but higher level than normal oper-
level 0 ating condition and lower than maximum operating condition.
3 Increased clamping Secondary pressure is at a fixed level and maximum pressure condition.
level 1
4 EDS1 Primary pulley pressure regulator.
5 EDS2 Secondary pressure regulator.
6 EDS3 Clutch pressure regulator.
7 Emergency mode Also called as “Limp Home Mode”. It is activated when:
• CAN bus is off.
• CAN ECU communication failed.
• CAN engine torque signals have an error.
• All engines and ABS related messages will be substituted immediately
(safety reactions):
• Throttle pedal is fixed.
• Engine torque map instead of the engine torque.
• Engine cooling temperature is fixed.
• Wheel speeds is substituted by the output shaft speed of the
gearbox.
• Engine speed is substituted by the hard wired engine speed if
available.
• The clutch will open and close faster, as if there is no calibration
on it.
• The maximum engine speed will be limited to 3200 rpm, even if
the throttle pedal is fully pressed.
• The maximum vehicle speed will be about 90 kph.
• The gearbox will shift but within a basic driving strategy.
• After 2 seconds, stepped AT (SAT) mode will not be possible
anymore and warning lamp will be on.
• The overall CVT working principle will become basic.

23 CVT
Dia-
gnosis Diagnosis PADT-II Dis-
No Probable cause Reaction from TCU
Code Item play
No
1. Short circuit to ground
Oil temperat- 2. Short circuit to battery 1. Warning lamp
1 P0710 ure sensor 3. Open circuit 2. Substitute transmis-
fault 4. Sensor defective sion oil temperature
Oil temperat- 5. TCU malfunction
ure High oil tem-
2 P0218 Oil cooler problem Warning lamp
perature
1. Oil cooler problem
Critical oil tem- 1. High side off
3 P1767 2. Oil level problem
perature 2. Warning lamp
3. Hydraulic unit defective
Primary pulley 2. Short circuit to battery
1. High side off
4 P2765 speed sensor 3. Open circuit
2. Warning lamp
fault 4. Sensor defective
5. TCU malfunction
Primary pul- 1. Wire harness problem
ley speed 2. TCU malfunction
Primary pulley 3. Sensor defective
1. High side off
5 P2766 speed unplaus- 4. Transmission cable harness
2. Warning lamp
ible problem
5. Vehicle cable harness
problem
Secondary pul- 2. Short circuit to battery
1. High side off
6 P0720 ley speed 3. Open circuit
2. Warning lamp
sensor fault 4. Sensor defective
5. TCU malfunction
Secondary 1. Wire harness problem
pulley speed 2. TCU malfunction
Secondary pul- 3. Sensor defective
1. High side off
7 P0721 ley speed un- 4. Transmission cable harness
2. Warning lamp
plausible problem
problem

CVT 23
Dia-
Code Item play
No
Secondary 2. Short circuit to battery
1. High side off
8 P0840 pressure sensor 3. Open circuit
2. Warning lamp
fault 4. Sensor defective
5. TCU malfunction
2. Short circuit to battery
Pressure sensor 1. High side off
9 P0641 3. Open circuit
supply fault 2. Warning lamp
4. Sensor defective
5. TCU malfunction
1. Too low pressure
Secondary 2. Oil level problem
pressure 3. Oil type problem
Secondary pul- 4. Clutch adaptation not
1. High side off
10 P1765 ley pressure complete
2. Warning lamp
too low 5. Too low torque from en-
gine
7. Oil pump defective
1. Too high pressure
Secondary pul- 2. Oil level problem
11 P1766 ley pressure 3. Oil type problem Warning lamp
too high 4. Hydraulic unit defective
DMS and 2. Short circuit to battery
1. High side off
12 P0651 speed sensor 3. Open circuit
2. Warning lamp
supply fault 4. Sensor defective
5. TCU malfunction
1. Transmission cable harness
problem
Drive mode 1. Warning lamp
13 P0706 Drive mode sensor single 2. Substitute lever posi-
problem
sensor line error tion
3. Drive mode sensor failure
4. TCU malfunction
problem
Drive mode
2. Vehicle cable harness 1. High side off
14 P0705 sensor multiple
problem 2. Warning lamp
lines error
4. TCU malfunction

23 CVT
Dia-
Code Item play
No
High side Short
1. Short circuit to battery 1. High side off
15 P0659 Circuit to Bat-
2. TCU malfunction 2. Warning lamp
tery
High side Short
Circuit to 1. High side off
Ground or 2. Warning lamp
3. TCU malfunction
Open Circuit
Double fault
High side 1. High side off
17 P0701 requiring high TCU malfunction
2. Warning lamp
side open
Battery or high 1. Battery problem
1. High side off
18 P0882 side voltage 2. Highside problem
2. Warning lamp
too low 3. TCU malfunction
1. High side off
19 P0883 side voltage 2. Highside problem
2. Warning lamp
too high 3. TCU malfunction
Watchdog test
Watchdog 1. High side off
20 P0702 failed (during TCU malfunction
test 2. Warning lamp
init)

CVT 23
Dia-
Code Item play
No
EDS1 (primary
pulley) Short 1. Short circuit to ground 1. High side off
21 P0962
Circuit to 2. Hydraulic unit defective 2. Warning lamp
Ground
EDS1 (primary
pulley) Short 1. Short circuit to battery 1. High side off
22 P0963
Circuit to Bat- 2. Hydraulic unit defective 2. Warning lamp
tery
EDS1 (primary
1. Open circuit 1. High side off
23 P0960 pulley) Open
2. Hydraulic unit defective 2. Warning lamp
Circuit
EDS2 (second-
ary pulley) 1. Short circuit to ground 1. High side off
24 P0966
Short Circuit to 2. Hydraulic unit defective 2. Warning lamp
Ground
EDS2 (second-
ary pulley) 1. Short circuit to battery 1. High side off
25 P0967
Short Circuit to 2. Hydraulic unit defective 2. Warning lamp
EDS (Pres- Battery
sure regulat-
EDS2 (second-
or) 1. Open circuit 1. High side off
26 P0964 ary pulley)
Open Circuit
EDS3 (clutch)
1. Short circuit to ground 1. High side off
27 P0902 Short Circuit to
Ground
EDS3 (clutch)
1. Short circuit to battery 1. High side off
28 P0903 Short Circuit to
Battery
EDS3 (clutch) 1. Open circuit 1. High side off
29 P0900
Open Circuit 2. Hydraulic unit defective 2. Warning lamp
problem
EDS current 2. Vehicle cable harness 1. High side off
30 P1761
fault problem 2. Warning lamp
3. Hydraulic unit failure
4. TCU malfunction
1. High side off
31 P1762 Current stuck TCU malfunction
2. Warning lamp
Shift lock Short
32 P0930 Circuit to
Ground
Shift lock Shift lock Short
Circuit to Bat- 1. High side off
tery or Open 2. Warning lamp
3. TCU malfunction
Circuit

23 CVT
Dia-
Code Item play
No
Backlight Short
34 P1768 Circuit to
Ground
Backlight Backlight Short
Circuit to Bat- 1. High side off
tery or Open 2. Warning lamp
3. TCU malfunction
Circuit
1. Oil level problem
Operation
Operation 2. Oil type problem 1. High side off
36 P0868 readiness time-
readiness 3. Oil pump defective 2. Warning lamp
out
1. Clutch adaptation not
Clutch (for- complete
1. High side off
37 P0811 ward or re- 2. Oil level problem
2. Warning lamp
verse) slipping 3. Oil type problem
Clutch 1. Oil level problem
2. Oil type problem
Clutch temper- 3. Clutch adaptation not 1. Warning lamp
38 P2787
ature too high complete 2. Clutch open
4. Throttle valve defective
5. TCU malfunction
2. Oil type problem
Ratio control 1. High side off
39 P0730 Ratio control 3. Sensor or hydraulic unit
fault 2. Warning lamp
defective
1. Idle speed controller
Engine speed problem
40 P1770 Warning lamp
too low 2. Check engine problem
3. Throttle body problem
Engine Hardwired en- 1. Engine problem
41 P0727 speed gine speed un- 2. Sensor defective Warning lamp
plausible 3. TCU malfunction
Powertrain
1. High side off
42 P0219 speed out of Fuel cut off problem
2. Warning lamp
range

CVT 23
Dia-
Code Item play
No
1. Torque of the engine is
too big
2. ECU malfunction
Insufficient Insufficient 4. Oil type problem
1. Warning lamp
43 P0944 clamping clamping force 5. Clutch adaptation not
2. Clutch open
force (VSM) (VSM) complete
6. Too low torque from en-
gine
AT mode sig- AT mode sig- 2. Open circuit
44 P1772 Warning lamp
nal nal error 3. Stepper motor switch mal-
function
EOL Clutch Ad-
Clutch adaptation not com-
45 P080A aption Not Fin- Warning lamp
plete
End Of Line ished
(EOL) clutch End Of Line
adaptation (EOL) clutch
46 P1774 Clutch adaptation error Warning lamp
adaptation er-
ror
1. Brake signal wiring prob-
Brake signal lem 1. Warning lamp
47 P0571 Brake signal
error 2. Brake switch problem 2. Brake signal on
3. TCU malfunction
Vehicle config-
Vehicle con- Invalid combination of TCU 1. High side off
48 U0301 uration mis-
figuration hardware and software 2. Warning lamp
match
1. Increased clamping
level 0
ABS function
49 U0415 ABS function ABS system problem 2. Substitute detection
error
function of blocked
and spinning wheels

23 CVT
Dia-
Code Item play
No
1. Warning lamp
2. Emergency mode act-
ive
3. No manual mode
level 1 (highest)
5. Substitute detection
function of blocked
and spinning wheels
6. Activate internal
driving strategy
7. Substitute engine
speed
1. Short circuit between CAN 8. Substitute engine
50 U0001 CAN bus off high and CAN low torque
2. TCU malfunction 9. Substitute engine
cooling water temper-
ature
10. Brake signal on
11. Accelerator pedal
value fixed
12. Substitute front left
CAN wheel speed
13. Substitute front right
wheel speed
14. Substitute rear left
wheel speed
15. Substitute rear right
wheel speed
level 0
2. Substitute detection
function of blocked
and spinning wheels
CAN ABS com- 1. ABS controller failure 3. Substitute front left
51 U0121 munication 2. CAN connection problem wheel speed
failed from ABS controller 4. Substitute front right
wheel speed
wheel speed
wheel speed
CAN ECU com- 1. Engine controller failure
52 U0100 munication 2. CAN connection problem
failed from engine controller

CVT 23
Dia-
Code Item play
No
1. Warning lamp
ive
3. No manual mode
level 0
driving strategy
speed
torque
cooling water temper-
ature
9. Accelerator pedal
value fixed
10. Stop transmitting on
CAN
CAN engine 1. Motor speed sensor defect- 1. Warning lamp
53 U1012 speed signal ive 2. Substitute engine
error 2. Sensor wiring problem speed
CAN accelerat- 1. Accelerator pedal sensor 1. Warning lamp
54 U1013 or pedal signal defective 2. Accelerator pedal
error 2. Sensor wiring problem value fixed
1. Warning lamp
ive
CAN engine
3. No manual mode
55 U1014 torque signals EMS controller problem
error
driving strategy
torque
level 0
CAN wheel 1. Wheel speed sensor defect- 2. Substitute detection
56 U1016 speed error - ive function of blocked
front left 2. Sensor wiring problem and spinning wheels
3. Substitute front left
wheel speed
level 0
front right 2. Sensor wiring problem and spinning wheels
3. Substitute front right
wheel speed
58 U1018

23 CVT
Dia-
Code Item play
No
level 0
speed error - ive function of blocked
rear left 2. Sensor wiring problem and spinning wheels
wheel speed
level 0
rear right 2. Sensor wiring problem and spinning wheels
wheel speed
ROAD TEST WCH023TSHOT11030
No Conditions for Test/Operation Judgement Check item Diagnos- Reference for checking
test/operation standard is code procedure in case of er-
No. ror
1 Ignition switch: Ignition switch Data list No. 18 ECU power - Communication with the
LOCK (OFF) (1) ON and 19 supply PADT—II is not possible
(1) Battery (Refer to page 23/185 )
voltage
2 Ignition switch: Selector lever Data list No. Drive mode P0651 Malfunction of drive
ON position 12, 13 and 14 sensor P0706 mode sensor (Refer to
Engine: (1) P (Lever posi- P0705 page 23/71 )
Stopped (2) R tion)
(3) N (1) P
(4) D (2) R
(3) N
(4) D
3 Ignition switch: Press Stepped Data list No. 44 A/T mode P1772 A/T mode signal error
ON A/T (SAT) LED indicator signal (Refer to page 23/149 )
Engine: mode button on outer panel
Stopped at gear shift to gearshift
switch to A/T
mode
4 Ignition switch: Accelerator Data list No. 50 APS U0001 CAN time-out error (En-
ON pedal and 52 U0100 gine) (Refer to page
Engine: (1) Fully closed (Throttle posi- 23/162 )
Stopped (2) Depressed tion)
Selector lever (3) Fully (1) 0% .
position: P opened (2) Gradually
increases from
(1)
(3) 100%

CVT 23
No. ror
Brake pedal (1) Data list No. 47 Stop lamp P0571 Malfunction of stop
Depressed (Brake status) switch light switch (Refer to
(2) Released (1) ON page 23/154 )
(2) OFF
Brake pedal Data list No. 32 Shift lock P0930 Malfunction of shift lock
pressed and and 33 (Shift P0931 (Refer to page 23/124 )
gear shift lever lock)
position down- ON
shift from P to
R position
5 Ignition switch: Perform the Engine can be Can the en- P0727 Engine does not start
START starting test in started. gine start? (Refer to page 23/144 )
the P or N posi-
tion.
6 Engine warm- Drive the Data list No. 6 CVT oil tem- P0710 Malfunction of CVT oil
ing up vehicle for 15 perature temperature sensor
minutes or sensor (Refer to page 23/43 )
more to raise
the CVT fluid
temperature
from 45 °C
(113 °F) to 100
°C (212 °F).
7 Engine: Idling • Selector lever Data list No. 40 Engine P1770 Abnormal engine speed
position: P and 41 speed P0219 (Refer to page 23/143 )
• Accelerator 600 to 800
pedal fully r/min
closed
Selector lever No abnormal Malfunction - Shock is experienced
position: P ? R shift shock at startup during N to D and/or N
?N?D Delay: 2 to R shifting operation.
seconds or less (Refer to page 23/16 )
- Vehicle Creeps in the N
Range. (Refer to page
23/16 )
Selector lever Data list No. 8 Secondary P0840 Malfunction of second-
position: N and 9 pressure P0641 ary pressure sensor
0.5 - 3.0 V sensor (Refer to page 23/61 )
Data list No. Primary P0962 Malfunction of primary
21, 22 and 23 pressure P0963 pressure regulator (Refer
0.45 - 0.75 A regulator P0960 to page 23/93 )
Data list No. Secondary P0966 Malfunction of second-
24, 25 and 26 pressure P0967 ary pressure regulator
0.45 - 0.75 A regulator P0964 (Refer to page 23/102 )
Data list No. Clutch pres- P0902 Malfunction of clutch
27, 28 and 29 sure regulat- P0903 pressure regulator (Refer
0.45 - 0.75 A or P0900 to page 23/111 )

23 CVT
No. ror
8 Selector lever Running Data list No. 4 Primary P2765 Malfunction of primary
position: D Nearly the speed speed sensor (Refer to
same as the sensor page 23/49 )
speedometer
display
Data list No. 6 Secondary P0720 Malfunction of the sec-
Nearly the speed ondary speed sensor
same as the sensor (Refer to page 23/55 )
speedometer
display
9 Selector lever Selector lever Data list No. 44 Poor acceler- P1772 Poor acceleration or in-
position: position (1) ation or incomplete shifting opera-
Stepped A/T (1) Stopped (1) 1st complete tion
(SAT) mode while idling (2) 2nd shifting op-
the engine. (3) 3rd eration
(2) Driving at a (4) 4th
constant speed (5) 5th
of 30 km/h in
2nd gear
(3) Driving at a
constant speed
of 35 km/h in
3rd gear
(4) Driving at a
constant speed
of 40 km/h in
4th gear
(5) Driving at a
constant speed
of 50 km/h in
5th gear
INSPECTION CHART FOR DIAGNOSIS CODE WCH023TSHOT11036
Diagnosis
No Diagnostic Item Reference Page
Code No
1 P0710
2 P0218 Oil temperature Refer to page 23/43
3 P1767
4 P2765
Primary pulley speed Refer to page 23/49
5 P2766
6 P0720
Secondary pulley speed Refer to page 23/55
7 P0721
8 P0840
9 P0641
Secondary pressure Refer to page 23/61
10 P1765
11 P1766

CVT 23
Diagnosis
Code No
12 P0651
13 P0706 Drive mode sensor Refer to page 23/71
14 P0705
15 P0659
16 P0658
17 P0701 High side Refer to page 23/77
18 P0882
19 P0883
20 P0702 Watchdog test Refer to page 23/92
21 P0962
22 P0963
23 P0960
24 P0966
25 P0967
26 P0964 EDS (Pressure regulator) Refer to page 23/93
27 P0902
28 P0903
29 P0900
30 P1761
31 P1762
32 P0930
Shift lock Refer to page 23/124
33 P0931
34 P1768
Backlight Refer to page 23/132
35 P1769
36 P0868 Operation readiness Refer to page 23/137
37 P0811
Clutch Refer to page 23/138
38 P2787
39 P0730 Ratio control Refer to page 23/140
40 P1770
41 P0727 Engine speed Refer to page 23/143
42 P0219
43 P0944 Insufficient clamping force Refer to page 23/146
44 P1772 AT mode signal Refer to page 23/149
45 P080A
End Of Line (EOL) clutch adaptation Refer to page 23/152
46 P1774
47 P0571 Brake signal Refer to page 23/154
48 U0301 Vehicle configuration Refer to page 23/156
49 U0415 ABS function Refer to page 23/158

23 CVT
Diagnosis
Code No
50 U0001
51 U0121
52 U0100
53 U1012
54 U1013
CAN Refer to page 23/162
55 U1014
56 U1016
57 U1017
58 U1018
59 U1019

CVT 23
P0710: OIL TEMPERATURE SENSOR FAULT WCH023TSHOT11009
OPERATION
The oil temperature sensor detects the temperature of the transmission oil.
CVT-TCU conducts fault detection by monitoring the terminal voltage of the CVT oil temperature
sensor.
DOIMC023R11187
CONNECTOR: A-40 CONNECTOR: C-32
DOIMC023R11229 DOIMC023R11230

23 CVT
OIL TEMPERATURE SENSOR
DOIMC023R11254
Fault code PADT–II display Reaction from TCU Probable cause
1. Warning lamp 2. Short circuit to battery
Oil temperature
P0710 2. Substitute transmission oil 3. Open circuit
sensor fault 4. Sensor defective
temperature
5. TCU malfunction
Function PADT–II display Check condition Standard value

1. Warming up
2. Drive for 15 minutes or
Dynamic data
Oil temperature more so that the transmis- < 120 °C (248 °F)
display
sion oil temperature be-
comes 70-90 °C (158-194 °F).

CVT 23
DOIMC023R11124

23 CVT
P0218: HIGH OIL TEMPERATURE WCH023TSHOT11010
OPERATION
CVT-TCU determines that the fault code is present when the transmission oil is overheated.
Transmission oil temperature reaches 120 °C (248 °F) or exceed the standard value.
DOIMC023R11254
High oil temperat-
P0218 Warning lamp Oil cooler problem
ure
1. Warming up
Dynamic data
display
comes 70-90 °C (158-194 °F).

CVT 23
DOIMC023R11202
P1767: CRITICAL OIL TEMPERATURE WCH023TSHOT11011
OPERATION
CVT-TCU determines that the fault code is present when the transmission oil is overheated.
Transmission oil temperature reaches 120 °C (248 °F) or exceed the standard value.
DOIMC023R11254

23 CVT
1. Oil cooler problem
Critical oil temper- 1. High side off 2. Oil level problem
P1767
ature 2. Warning lamp 3. Hydraulic unit defective

1. Warming up
Dynamic data
display
comes 70-90 °C (158-194 °F).
DOIMC023R11203

CVT 23
P2765: PRIMARY PULLEY SPEED SENSOR FAULT WCH023TSHOT11012
OPERATION
The primary pulley speed sensor detects the input revolution speed and sends a signal to the CVT-
TCU.
CVT-TCU determines that the malfunction is present when the primary pulley speed sensor value
changes abruptly or when there is a discrepancy between this sensor and other sensors in sensor
reading.
DOIMC023R11188

23 CVT
PRIMARY PULLEY SPEED SENSOR
DOIMC023R11235
Primary pulley 1. High side off 3. Open circuit
P2765
speed sensor fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction

1. Selector lever position: D
Dynamic data Primary pulley Approximately similar as the ta-
2. Driving at constant speed
display speed chometer display
of 50 km/h (31.07 mph)

CVT 23
DOIMC023R11125

23 CVT
P2766: PRIMARY PULLEY SPEED UNPLAUSIBLE WCH023TSHOT11013
OPERATION
The primary pulley speed sensor detects the input revolution speed and sends a signal to the CVT-
TCU.
CVT-TCU determines that the malfunction is present when the primary pulley speed sensor value
reading.
DOIMC023R11197

CVT 23
CONNECTOR: C-06 PRIMARY PULLEY SPEED SENSOR
1. Wire harness problem
2. TCU malfunction
3. Sensor defective
Primary pulley 1. High side off 4. Transmission cable harness
P2766
speed unplausible 2. Warning lamp problem
5. Vehicle cable harness prob-
lem

Engine speed 1. Selector lever position: D ± 850 rpm at engine idling
Dynamic data Output speed 2. Driving at constant speed Tachometer display X 5.76 (rpm)
display of 50 km/h (31.07 mph)
Vehicle speed-out-
Value increase as vehicle moves
put speed

23 CVT
DOIMC023R11206

CVT 23
P0720: SECONDARY PULLEY SPEED SENSOR FAULT WCH023TSHOT11014
OPERATION
The secondary pulley speed sensor detects the output revolution speed and sends a signal to the CVT-
TCU.
CVT-TCU determines that the malfunction is present when the secondary pulley speed sensor value
reading.
DOIMC023R11189

23 CVT
SECONDARY PULLEY SPEED SENSOR
DOIMC023R11255
Secondary pulley 1. High side off 3. Open circuit
P0720
speed sensor fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction

1. Selector lever position: D
Dynamic data Secondary pulley
2. Driving at constant speed Tachometer display X 5.76 (rpm)
display speed
of 50 km/h (31.07 mph)

CVT 23
DOIMC023R11126

23 CVT
P0721: SECONDARY PULLEY SPEED UNPLAUSIBLE WCH023TSHOT11015
OPERATION
The secondary pulley speed sensor detects the output revolution speed and sends a signal to the CVT-
TCU.
CVT-TCU determines that the malfunction is present when the secondary pulley speed sensor value
reading.
DOIMC023R11197

CVT 23
CONNECTOR: C-06 SECONDARY PULLEY SPEED SENSOR
1. Wire harness problem
2. TCU malfunction
3. Sensor defective
Secondary pulley 1. High side off 4. Transmission cable harness
P0721
speed unplausible 2. Warning lamp problem
5. Vehicle cable harness prob-
lem

Engine speed 1. Selector lever position: D ± 850 rpm at engine idling
Primary pulley 2. Driving at constant speed Same as the tachometer display
Dynamic data of 50 km/h (31.07 mph)
speed (rpm)
display
Vehicle speed-out-
Value increase as vehicle moves
put speed

23 CVT
DOIMC023R11205

CVT 23
P0840: SECONDARY PRESSURE SENSOR FAULT WCH023TSHOT11016
OPERATION
The secondary pressure sensor detects the output pressure of the transmission.
CVT-TCU conducts fault detection by monitoring the output voltage of the secondary pressure sensor.
DOIMC023R11190

23 CVT
SECONDARY PRESSURE SENSOR
DOIMC023R11253
Secondary pressure 1. High side off 3. Open circuit
P0840
sensor fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction

1. Commanded pul-
Dynamic data ley 2 pressure Pulley 2 pressure operation
Vehicle being driven
display 2. Measured pulley 2 Approximately similar value
pressure

CVT 23
DOIMC023R11127

23 CVT
P0641: PRESSURE SENSOR SUPPLY FAULT WCH023TSHOT11017
OPERATION
DOIMC023R11190

CVT 23
DOIMC023R11253
Pressure sensor supply 1. High side off 3. Open circuit
P0641
fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction

Dynamic data
5.0 V sensor voltage Ignition ON 5.0 V
display

23 CVT
DOIMC023R11142

CVT 23
P1765: SECONDARY PULLEY PRESSURE TOO LOW WCH023TSHOT11046
OPERATION
DOIMC023R11253
1. Too low pressure
3. Oil type problem
Secondary pulley 1. High side off 4. Clutch adaptation not com-
P1765 plete
pressure too low 2. Warning lamp
5. Too low torque from engine
Function PADT–II display Check Condition Standard Value

1. C o m m a n d e d
pulley 2 pres-
Dynamic data Pulley 2 pressure operation
sure Vehicle being driven
display Approximately similar value
2. Measured pul-
ley 2 pressure

23 CVT
DOIMC023R11162

CVT 23
P1766: SECONDARY PULLEY PRESSURE TOO HIGH WCH023TSHOT11047
OPERATION
DOIMC023R11253
1. Too high pressure
Secondary pulley 1. High side off 3. Oil type problem
P1766
pressure too high 2. Warning lamp 4. Hydraulic unit defective

pulley 2 pres-
Dynamic data Pulley 2 pressure operation
2. Measured pul-
ley 2 pressure

23 CVT
DOIMC023R11171

CVT 23
P0651: DMS AND SPEED SENSOR SUPPLY FAULT WCH023TSHOT11018
OPERATION
The drive mode sensor ( DMS) detects the selector lever position when the shift lever is in the N or P
shift position. CVT-TCU monitors the signal from the DMS and determines if the abnormal input is
present or not.
The secondary pressure sensor detects the output pressure of the transmission. CVT-TCU conducts
fault detection by monitoring the output voltage of the secondary pressure sensor.
DOIMC023R11191

23 CVT
DRIVE MODE SENSOR (DMS) PRIMARY PULLEY SPEED SENSOR
SECONDARY PULLEY SPEED SENSOR
DOIMC023R11255
DMS and speed sensor 1. High side off 3. Open circuit
P0651
supply fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction

Dynamic data
8.4 V sensor voltage Ignition ON 8.4 V
display

CVT 23
DOIMC023R11143

23 CVT
P0706: DRIVE MODE SENSOR SINGLE LINE ERROR WCH023TSHOT11019
OPERATION
present or not.
DRIVE MODE SENSOR (DMS)
DOIMC023R11236
problem
Drive mode sensor 1. Warning lamp 2. Vehicle cable harness
P0706 problem
single line error 2. Substitute lever position
4. TCU malfunction

CVT 23
DOIMC023R11226
P0705: DRIVE MODE SENSOR MULTIPLE LINES ERROR WCH023TSHOT11020
OPERATION
present or not.
DRIVE MODE SENSOR (DMS)
DOIMC023R11236

23 CVT
problem
Drive mode sensor 1. High side off 2. Vehicle cable harness
P0705 problem
multiple lines error 2. Warning lamp
4. TCU malfunction
DOIMC023R11227

CVT 23
P0659: HIGH SIDE SHORT CIRCUIT TO BATTERY WCH023TSHOT11021
OPERATION
High side is a supply voltage for the 3 pressure regulators (EDS1, EDS2 and EDS3).
CVT-TCU conducts fault detection by monitoring the output voltage of the 3 pressure regulators
(EDS1, EDS2 and EDS3).
DOIMC023R11192

23 CVT
EDS1 (PRIMARY PRESSURE REGULATOR) EDS2 (SECONDARY PRESSURE REGULATOR)
EDS3 (CLUTCH PRESSURE REGULATOR)
DOIMC023R11258
High side Short 1. High side off 1. Short circuit to battery
P0659 2. TCU malfunction
Circuit to Battery 2. Warning lamp

Dynamic data High side voltage > 3.4 V
Ignition ON
display Battery voltage 11.6 - 12.0 V

CVT 23
DOIMC023R11131

23 CVT
P0658: HIGH SIDE SHORT CIRCUIT TO GROUND OR OPEN CIRCUIT WCH023TSHOT11022
OPERATION
DOIMC023R11192

CVT 23
DOIMC023R11258
High side Short 1. High side off 2. Open circuit
P0658
Circuit to Battery 2. Warning lamp 3. TCU malfunction

Ignition ON

23 CVT
DOIMC023R11130

CVT 23
P0701: DOUBLE FAULT REQUIRING HIGH SIDE OPEN WCH023TSHOT11023
OPERATION
DOIMC023R11258
Double fault re-
1. High side off
P0701 quiring high side TCU malfunction
2. Warning lamp
open
Ignition ON

23 CVT
DOIMC023R11168
P0882: BATTERY OR HIGH SIDE VOLTAGE TOO LOW WCH023TSHOT11024
OPERATION
(EDS1, EDS2 and EDS3). It monitors if power supply system is normal (3.4 V).
DOIMC023R11199

CVT 23
CONNECTOR: A-16 CONNECTOR: A-21

23 CVT
DOIMC023R11258
1. High side off 2. Highside problem
P0822 side voltage too
2. Warning lamp 3. TCU malfunction
low

Ignition ON

CVT 23
DOIMC023R11212

23 CVT
P0883: BATTERY OR HIGH SIDE VOLTAGE TOO HIGH WCH023TSHOT11025
OPERATION
(EDS1, EDS2 and EDS3). It monitors if power supply system is normal (3.4 V).
DOIMC023R11199

CVT 23
DOIMC023R11258
1. High side off 2. Highside problem
P0883 side voltage too
high

23 CVT

Ignition ON

CVT 23
DOIMC023R11213

23 CVT
P0702: WATCHDOG TEST FAILED (DURING INITIALIZATION) WCH023TSHOT11026
OPERATION
It seems that there was a miscommunication or a software incompatibility with the PADT-II. There is
an internal failure in the transmission control unit.
Watchdog test 1. High side off
P0702 TCU malfunction
failed (during init) 2. Warning lamp
DOIMC023R11132

CVT 23
P0962: EDS1 (PRIMARY PULLEY) SHORT CIRCUIT TO GROUND WCH023TSHOT11037
OPERATION
A pressure regulator is a valve that automatically cut-off the flow of transmission oil at a certain
pressure. Regulators are used to allow high-pressure fluid supply lines to be reduced to safe and usable
pressures for various applications.
CVT-TCU determines malfunction by detecting the abnormality in the primary pressure regulator
valve.
DOIMC023R11192

23 CVT
EDS1 (PRIMARY PRESSURE REGULATOR)
DOIMC023R11256
EDS1 (primary pul- 1. Short circuit to ground
1. High side off
P0962 ley) short circuit to 2. Hydraulic unit defective
2. Warning lamp
Ground
1. C o m m a n d e d 1. Warming up
current of Pul- 2. Drive for 15 minutes or
ley 1 Pressure more so that the transmis-
Pulley 1 pressure regulator con-
Dynamic data Regulator sion oil temperature be-
dition
display 2. Measured cur- comes 70-90 °C (158-194 °F).
Approximately similar value
rent of Pulley
1 Pressure Reg-
ulator

CVT 23
DOIMC023R11133

23 CVT
P0963: EDS1 (PRIMARY PULLEY) SHORT CIRCUIT TO BATTERY WCH023TSHOT11038
OPERATION
valve.
DOIMC023R11192

CVT 23
DOIMC023R11256
EDS1 (primary pul- 1. Short circuit to battery
1. High side off
P0963 ley) short circuit to 2. Hydraulic unit defective
2. Warning lamp
Battery
dition
rent of Pulley
1 Pressure Reg-
ulator

23 CVT
DOIMC023R11134

CVT 23
P0960: EDS1 (PRIMARY PULLEY) OPEN CIRCUIT WCH023TSHOT11039
OPERATION
valve.
DOIMC023R11192

23 CVT
DOIMC023R11256
EDS1 (primary pul- 1. High side off 1. Open circuit
P0960 2. Hydraulic unit defective
ley) open circuit 2. Warning lamp

dition
rent of Pulley
1 Pressure Reg-
ulator

CVT 23
DOIMC023R11135

23 CVT
P0966: EDS2 (SECONDARY PULLEY) SHORT CIRCUIT TO GROUND WCH023TSHOT11040
OPERATION
CVT-TCU determines malfunction by detecting the abnormality in the secondary pressure regulator
valve.
DOIMC023R11192

CVT 23
EDS2 (SECONDARY PRESSURE REGULATOR)
DOIMC023R11257
EDS2 (secondary 1. Short circuit to ground
1. High side off
P0966 pulley) short cir- 2. Hydraulic unit defective
2. Warning lamp
cuit to Ground
dition
rent of Pulley
2 Pressure Reg-
ulator

23 CVT
DOIMC023R11136

CVT 23
P0967: EDS2 (SECONDARY PULLEY) SHORT CIRCUIT TO BATTERY WCH023TSHOT11041
OPERATION
valve.
DOIMC023R11192

23 CVT
DOIMC023R11257
EDS2 (secondary 1. Short circuit to battery
1. High side off
P0967 pulley) short cir- 2. Hydraulic unit defective
2. Warning lamp
cuit to Battery
dition
rent of Pulley
2 Pressure Reg-
ulator

CVT 23
DOIMC023R11137

23 CVT
P0964: EDS2 (SECONDARY PULLEY) OPEN CIRCUIT WCH023TSHOT11042
OPERATION
valve.
DOIMC023R11192

CVT 23
DOIMC023R11257
EDS2 (secondary 1. Open circuit
1. High side off
P0964 pulley) open cir- 2. Hydraulic unit defective
2. Warning lamp
cuit
dition
rent of Pulley
2 Pressure Reg-
ulator

23 CVT
DOIMC023R11138

CVT 23
P0902: EDS3 (CLUTCH) SHORT CIRCUIT TO GROUND WCH023TSHOT11043
OPERATION
CVT-TCU determines malfunction by detecting the abnormality in the clutch pressure regulator valve.
DOIMC023R11192

23 CVT
DOIMC023R11258
EDS3 (clutch) short 1. High side off 1. Short circuit to ground
circuit to Ground 2. Warning lamp

current of 2. Drive for 15 minutes or
Clutch Pressure more so that the transmis-
Clutch pressure regulator condi-
tion
rent of Clutch
Pressure Regu-
lator

CVT 23
DOIMC023R11139

23 CVT
P0903: EDS3 (CLUTCH) SHORT CIRCUIT TO BATTERY WCH023TSHOT11044
OPERATION
DOIMC023R11192

CVT 23
DOIMC023R11258
EDS3 (clutch) short 1. High side off 1. Short circuit to battery
circuit to Battery 2. Warning lamp

tion
rent of Clutch
Pressure Regu-
lator

23 CVT
DOIMC023R11140

CVT 23
P0900: EDS3 (CLUTCH) OPEN CIRCUIT WCH023TSHOT11045
OPERATION
DOIMC023R11192

23 CVT
DOIMC023R11258
EDS3 (clutch) open 1. High side off 1. Open circuit
circuit 2. Warning lamp

tion
rent of Clutch
Pressure Regu-
lator

CVT 23
DOIMC023R11141
P1761: EDS CURRENT FAULT WCH023TSHOT11048
OPERATION
CVT-TCU determines malfunction by detecting the abnormality in the pressure regulator current.

23 CVT
DOIMC023R11258
problem
1. High side off 2. Vehicle cable harness prob-
P1761 EDS current fault lem
2. Warning lamp
3. Hydraulic unit failure
4. TCU malfunction

1. Actual current
of pulley 1
pressure regu-
lator
current of pul-
ley 1 pressure
regulator
3. Actual current
of pulley 2 1. Warming up
pressure regu- 2. Drive for 15 minutes or
Dynamic data Pressure regulator condition
lator more so that the transmis-
4. C o m m a n d e d sion oil temperature be-
current of pul- comes 70-90 °C (158-194 °F).
ley 2 pressure
regulator
5. Actual current
of clutch pres-
sure regulator
current of
clutch pressure
regulator

CVT 23
DOIMC023R11224
P1762: CURRENT STUCK WCH023TSHOT11065
OPERATION
A pressure regulator is a valve that automatically cuts off the flow of transmission oil at a certain
valve.

23 CVT
DOIMC023R11258
1. High side off
P1762 Current stuck TCU malfunction
2. Warning lamp

CVT 23

1. Actual current
of pulley 1
pressure regu-
lator
current of pul-
ley 1 pressure
regulator
3. Actual current
of pulley 2 1. Warming up
pressure regu- 2. Drive for 15 minutes or
Dynamic data Pressure regulator condition
lator more so that the transmis-
4. C o m m a n d e d sion oil temperature be-
current of pul- comes 70-90 °C (158-194 °F).
ley 2 pressure
regulator
5. Actual current
of clutch pres-
sure regulator
current of
clutch pressure
regulator
DOIMC023R11211

23 CVT
P0930: SHIFT LOCK SHORT CIRCUIT TO GROUND WCH023TSHOT11049
OPERATION
The shift lock is used to allow the gear lever to be moved from P (parking) to other position. The se-
lector lever cannot be shifted from “P” position to any other position unless the ignition switch is in
the ON position and the brake pedal is depressed.
CVT-TCU conducts fault detection by monitoring the terminal voltage of the shift lock switch.
DOIMC023R11193

CVT 23
CONNECTOR: C-32 CONNECTOR: C-17
CONNECTOR: C-14 CONNECTOR: A-38x
SHIFT LOCK SOLENOID STOP LAMP SWITCH
Shift lock short cir- 1. High side off 1. Short circuit to ground
cuit to Ground 2. Warning lamp

23 CVT
DOIMC023R11164

CVT 23
P0931: SHIFT LOCK SHORT CIRCUIT TO BATTERY OR OPEN CIRCUIT WCH023TSHOT11050
OPERATION
The shift lock is used to allow the gear lever to be moved from P (parking) to other position. The se-
lector lever cannot be shifted from “P” position to any other position unless the ignition switch is in
the ON position and the brake pedal is depressed.
CVT-TCU conducts fault detection by monitoring the terminal voltage of the shift lock switch.

23 CVT
DOIMC023R11194

CVT 23
CONNECTOR: A-21 CONNECTOR: E-20

23 CVT
SHIFT LOCK SOLENOID STOP LAMP SWITCH
Shift lock short cir- 1. Short circuit to battery
1. High side off 2. Open circuit
P0931 cuit to Battery or
open circuit

CVT 23
DOIMC023R11163

23 CVT
P1768: BACKLIGHT SHORT CIRCUIT TO GROUND WCH023TSHOT11051
OPERATION
CVT-TCU detects malfunction using the backlight switch signal sent from the engine ECU.
DOIMC023R11195

CVT 23
CONNECTOR: C-17
DOIMC023R11246
Backlight short cir- 1. High side off 1. Short circuit to ground
cuit to Ground 2. Warning lamp
DOIMC023R11165

23 CVT
P1769: BACKLIGHT SHORT CIRCUIT TO BATTERY OR OPEN CIRCUIT WCH023TSHOT11052
OPERATION
CVT-TCU detects malfunction using the backlight switch signal sent from the engine ECU.

CVT 23
DOIMC023R11196

23 CVT
CONNECTOR: A-39x CONNECTOR: A-16
CONNECTOR: A-19
DOIMC023R11239
Backlight short cir- 1. Short circuit to battery
1. High side off 2. Open circuit
P1769 cuit to Battery or
open circuit

CVT 23
DOIMC023R11167
P0868: OPERATION READINESS TIME OUT WCH023TSHOT11053
OPERATION
Operation readiness is the end state of operation planning.
Operation readi- 1. High side off 2. Oil type problem
P0868 3. Oil pump defective
ness time out 2. Warning lamp

23 CVT
DOIMC023R11169
P0811: CLUTCH (FORWARD OR REVERSE) SLIPPING WCH023TSHOT11054
OPERATION
There are 2 multi plate wet clutch packs; forward and reverse. Each pack has 3 friction plates providing
6 friction surfaces. The hydraulic pressure controls the clutches to allow the vehicle to move away
smoothly by every throttle opening. By controlling the clutch slip it also allows the vehicle to be held
stationary after the drive gear is engaged. Oil from the oil cooler is directed to the clutch plates to
prevent overheating of the friction surfaces.
1. Clutch adaptation not com-
plete
Clutch (forward or 1. High side off 2. Oil level problem
P0811
reverse) slipping 2. Warning lamp 3. Oil type problem

CVT 23
DOIMC023R11166
P2787: CLUTCH TEMPERATURE TOO HIGH WCH023TSHOT11055
OPERATION
There are 2 multi plate wet clutch packs; forward and reverse. Each pack has 3 friction plates providing
6 friction surfaces. The hydraulic pressure controls the clutches to allow the vehicle to move away
smoothly by every throttle opening. By controlling the clutch slip it also allows the vehicle to be held
stationary after the drive gear is engaged. Oil from the oil cooler is directed to the clutch plates to
prevent overheating of the friction surfaces.
2. Oil type problem
Clutch temperat- 1. Warning lamp 3. Clutch adaptation not com-
P2787 plete
ure too high 2. Clutch open
4. Throttle valve defective
5. TCU malfunction

23 CVT
DOIMC023R11214
P0730: RATIO CONTROL FAULT WCH023TSHOT11056
OPERATION
This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by
CVT-TCU.
If the actual gear position is higher than the position supposed by CVT-TCU, the slip ratio will be more
than normal. In case the ratio exceeds the specified value, CVT-TCU judges this diagnosis malfunction.

CVT 23
2. Oil type problem
1. High side off 3. Sensor or hydraulic unit de-
P0730 Ratio control fault
2. Warning lamp fective

Primary pulley Approximately same as tachomet-
speed er display
Engine at idling
Secondary pulley 2.43 X Primary pulley speed
speed value
Dynamic data
display 1. C o m m a n d e d
pulley 2 pres-
Pulley 2 pressure operation
2. Measure pulley
2 pressure

23 CVT
DOIMC023R11170

CVT 23
P1770: ENGINE SPEED TOO LOW WCH023TSHOT11062
OPERATION
The engine speed signal is transmitted from engine ECU to CVT-TCU via CAN communication line.
1. Idle speed controller problem
Engine speed too 2. Check engine problem
P1770 Warning lamp
low 3. Throttle body problem

1. Warming up
Dynamic data
Engine speed more so that the transmis- ±850 rpm (Idling)
display
comes 70-90 °C (158-194 °F).
DOIMC023R11210

23 CVT
P0727: HARDWIRED ENGINE SPEED UNPLAUSIBLE WCH023TSHOT11063
OPERATION
The engine speed signal is transmitted from engine ECU to CVT-TCU via CAN communication line and
pin no. 87 (CVT-TCU) as the engine speed back-up signal.
DOIMC023R11200

CVT 23
1. Engine problem
Hardwired engine 2. Sensor defective
P0727 Warning lamp
speed unplausible 3. TCU malfunction

1. Warming up
Dynamic data
display
comes 70-90 °C (158-194 °F).
DOIMC023R11223

23 CVT
P0219: POWERTRAIN SPEED OUT OF RANGE WCH023TSHOT11057
OPERATION
Indicates the vehicle has been operated in a manner which caused the engine speed to exceed a cal-
ibrated limit. The engine RPM is continuously monitored and evaluated by the engine ECU. The fault
code is set when the RPM exceeds the calibrated limit set within the engine ECU.
Powertrain speed 1. High side off
P0219 Fuel cut off problem
out of range 2. Warning lamp
1. Warming up
Dynamic data
display
comes 70-90 °C (158-194 °F).
DOIMC023R11204
P0944: INSUFFICIENT CLAMPING FORCE (VSM) WCH023TSHOT11058
OPERATION
The clamping force management ensures that the pressure levels necessary to provide the demanded
forces at the variator (to prevent belt slip). It have minimized impact on the efficiency of the transmis-
sion, in order to minimize fuel consumption (high efficiency).

CVT 23
1. Torque of the engine is too
big
2. ECU malfunction
Insufficient clamp- 1. Warning lamp 4. Oil type problem
P0944 5. Clutch adaptation not com-
ing force (VSM) 2. Clutch open
plete
6. Too low torque from engine

23 CVT
DOIMC023R11207

CVT 23
P1772: AT MODE SIGNAL ERROR WCH023TSHOT11064
OPERATION
AT mode is a condition when the vehicle is operating in conventional automatic transmission.
CVT-TCU conducts fault detection by monitoring the error signal from stepped auto (SAT) switch.
DOIMC023R11198
CONNECTOR: E-20 CONNECTOR: C-32

23 CVT
SAT SWITCH
DOIMC023R11234
AT mode signal er- 2. Open circuit
P1772 Warning lamp 3. Stepper motor switch mal-
ror
function

Unknown / First Manual Gear /
Second Manual Gear / Third
Manual Gear / Fourth Manual
Gear / Fifth Manual Gear / R (re-
Dynamic data verse) / SAT; First Gear / SAT;
Lever position Ignition ON
display Second Gear / SAT;Third Gear /
SAT; Fourth Gear / SAT; Fifth
Gear / P (Park) / N (Neutral) / D
(Drive) / S (Sport) / L (Low) / Inval-
id (error)

CVT 23
DOIMC023R11208

23 CVT
P080A: EOL CLUTCH ADAPTATION NOT FINISHED WCH023TSHOT11060
OPERATION
The clutches need an adaptation to compensate for tolerances after uploading new software in the
TCU, replacement of TCU or replacement of transmission. However, the fault code can come out when
clutch adaptation is not optimal or complete.
EOL clutch adapta-
P080A Warning lamp Clutch adaptation not complete
tion not finished
No Error / Unstable Engine
torque / Air-cond ON / Pressure
Dynamic data EOL clutch adapta-
Ignition ON too high / Engine speed too low
display tion error
/ Engine speed too high / Too
many abortions
DOIMC023R11209
P1774: END OF LINE (EOL) CLUTCH ADAPTATION ERROR WCH023TSHOT11061
OPERATION
The clutches need an adaptation to compensate for tolerances after uploading new software in the
TCU, replacement of TCU or replacement of transmission. However, the fault code can come out when
clutch adaptation is not optimal or complete.

CVT 23
End of Line (EOL)
P1774 clutch adaptation Warning lamp Clutch adaptation error
error
No Error / Unstable Engine
torque / Air-cond ON / Pressure
Dynamic data EOL clutch adapta-
Ignition ON too high / Engine speed too low
display tion error
/ Engine speed too high / Too
many abortions
DOIMC023R11209

23 CVT
P0571: BRAKE SIGNAL ERROR WCH023TSHOT11066
OPERATION
When the brake pedal is depressed, the stop light switch sends a signal to the CVT-TCU.
The CVT-TCU will sets a fault code when the stop light switch does not turn off even once the vehicle
is driven.
DOIMC023R11201
CONNECTOR: E-04 CONNECTOR: C-32

CVT 23
1. Brake signal wiring problem
1. Warning lamp 2. Brake switch problem
P0571 Brake signal error
2. Brake signal on 3. TCU malfunction

Dynamic data Brake status OFF/ON
Ignition ON
display Brake signal fault OK/FAIL

23 CVT
DOIMC023R11228
U0301: VEHICLE CONFIGURATION MISMATCH WCH023TSHOT11067
OPERATION
The fault code is sets when the configuration between two or more modules do not match.
Vehicle configura- 1. High side off Invalid combination of TCU
U0301
tion mismatch 2. Warning lamp hardware and software

CVT 23
DOIMC023R11225

23 CVT
U0415: ABS FUNCTION ERROR WCH023TSHOT11068
OPERATION
CVT—TCU receives the data (such as wheel speed sensor signal) from ABS-ECU via the CAN bus lines.
If it detects malfunction of the wheel speed signal, it interrupts the system.

CVT 23
DOIMC023R11282

23 CVT
CONNECTOR: C-14 CONNECTOR: A-20
CONNECTOR: A-43
DOIMC023R11267
1. Increased clamping level 0
2. Substitute detection func-
U0415 ABS function error ABS system problem
tion of blocked and spin-
ning wheels

CVT 23
DOIMC023R11215

23 CVT
U0001: CAN BUS OFF WCH023TSHOT11069
OPERATION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-
vehicle multiplex communication line with high data communication speed and excellent malfunction
detection ability. Many electronic control units are equipped onto a vehicle, and each control unit
shares information and links with other control units during operation (not independent). In CAN
communication, control units are connected with 2 communication lines (CAN-H and CAN-L) allowing
a high rate of information transmission with less wiring. Each control unit transmits and receives data
but selectively reads required data only.
DOIMC023R11260

CVT 23
CONNECTOR: D-06
DOIMC023R11248

23 CVT
1. Warning lamp
2. Emergency mode active
3. No manual mode
(highest)
ning wheels
6. Activate internal driving
strategy
7. Substitute engine speed
8. Substitute engine torque 1. Short circuit between CAN
U0001 CAN bus off 9. Substitute engine cooling high and CAN low
water temperature 2. TCU malfunction
10. Brake signal on
11. Accelerator pedal value
fixed
12. Substitute front left wheel
speed
13. Substitute front right wheel
speed
14. Substitute rear left wheel
speed
15. Substitute rear right wheel
speed

CVT 23
DOIMC023R11216
U0121: CAN ABS COMMUNICATION FAILED WCH023TSHOT11070
OPERATION
ECU receives the data (such as ABS sensor signal, ABS operation signal) via the CAN bus lines. If it
cannot receive such data, it interrupts the system.
ning wheels
3. Substitute front left wheel 1. ABS controller failure
CAN ABS commnu- speed 2. CAN connection problem
U0121
cation failed 4. Substitute front right wheel from ABS controller
speed
speed
speed

23 CVT
DOIMC023R11217
U0100: CAN ECU COMMUNICATION FAILED WCH023TSHOT11071
OPERATION
ECU receives the data (such as engine controller signal, engine operation signal) via the CAN bus lines.
If it cannot receive such data, it interrupts the system.
1. Warning lamp
3. No manual mode
5. Activate internal driving
strategy 1. Engine controller failure
CAN ECU commnu- 2. CAN connection problem
U0100 6. Substitute engine speed
cation failed from engine controller
7. Substitute engine torque
8. Substitute engine cooling
water temperature
9. Accelerator pedal value
fixed
10. Stop transmitting on CAN
DOIMC023R11218

CVT 23
U1012: CAN ENGINE SPEED SIGNAL ERROR WCH023TSHOT11072
OPERATION
ECU receives the data (such as motor controller signal, motor speed sensor signal) via the CAN bus
lines. If it cannot receive such data, it interrupts the system.
CAN engine speed 1. Warning lamp 1. Motor speed sensor defective
U1012 2. Sensor wiring problem
signal error 2. Substitute engine speed

1. Warming up
Dynamic data more so that the transmis-
Engine speed ± 850 rpm (Idling)
display sion oil temperature be-
comes 70 - 90 °C (158 - 194
°F)
DOIMC023R11219
U1013: CAN ACCELERATOR PEDAL SIGNAL ERROR WCH023TSHOT11073
OPERATION
ECU receives the data (such as EMS controller signal, accelerator pedal sensor signal) via the CAN bus
lines. If it cannot receive such data, it interrupts the system.
1. Warning lamp 1. Accelerator pedal sensor de-
CAN accelerator fective
U1013 2. Accelerator pedal value
pedal signal error 2. Sensor wiring problem
fixed

23 CVT
DOIMC023R11220
U1014: CAN ENGINE TORQUE SIGNAL ERROR WCH023TSHOT11074
OPERATION
ECU receives the data (such as EMS controller signal) via the CAN bus lines. If it cannot receive such
data, it interrupts the system.
1. Warning lamp
CAN engine 3. No manual mode
U1014 EMS controller problem
torque signal error 4. Activate internal driving
strategy
5. Substitute engine torque
1. Engine torque Engine torque data status —
Dynamic data —CAN Data sends by engine ECU and
Vehicle being driven
display 2. Engine torque data requests by CVT-TCU
— TCU (Approximately similar value)
DOIMC023R11221

CVT 23
U1016: CAN WHEEL SPEED ERROR — FRONT LEFT WCH023TSHOT11075
OPERATION
ECU receives the data (such as ABS controller signal, wheel speed sensor signal) via the CAN bus lines.

23 CVT
DOIMC023R11269

CVT 23

23 CVT
CONNECTOR: C-32 CONNECTOR: D-06
CAN wheel speed tion of blocked and spin- 1. Wheel speed sensor defective
sensor — front left ning wheels
3. Substitute front left wheel
speed
DOIMC023R11222

CVT 23
U1017: CAN WHEEL SPEED ERROR — FRONT RIGHT WCH023TSHOT11076
OPERATION

23 CVT
DOIMC023R11269

CVT 23

23 CVT
CAN wheel speed
tion of blocked and spin- 1. Wheel speed sensor defective
U1017 sensor — front 2. Sensor wiring problem
ning wheels
right
3. Substitute front right wheel
speed
DOIMC023R11222

CVT 23
U1018: CAN WHEEL SPEED ERROR — REAR LEFT WCH023TSHOT11077
OPERATION

23 CVT
DOIMC023R11270

CVT 23
CAN wheel speed tion of blocked and spin- 1. Wheel speed sensor defective
sensor — rear left ning wheels
speed

23 CVT
DOIMC023R11222

CVT 23
U1019: CAN WHEEL SPEED ERROR — REAR RIGHT WCH023TSHOT11078
OPERATION

23 CVT
DOIMC023R11270

CVT 23
CAN wheel speed
tion of blocked and spin- 1. Wheel speed sensor defective
U1019 sensor — rear 2. Sensor wiring problem
ning wheels
right
speed

23 CVT
DOIMC023R11222
TROUBLE SYMPTOM WCH023TSHOT11079
TROUBLE SYMPTOM CHART

CAUTION:
During diagnosis, a diagnosis code associated with other system may be set when the ignition
switch is turned on with connector(s) disconnected. On completion, confirm all systems for diagnosis
code(s). If diagnosis code(s) are set, erase them all.
Trouble symptom Inspection procedure number Reference page
Communication with the PADT-II is not possible 1 23/185
(CVT-TCU cannot be turned ON)
Vehicle creeps in the N range 2 23/187
Shock is experienced during N to D and/or N to 3 23/187
R shifting operation
Poor acceleration or incomplete shifting opera- 4 23/188
tion
Gears cannot be changed in SAT (Stepped 5 23/190
Automatic Transmission) mode

CVT 23
SYMPTOM PROCEDURES / 185
SYMPTOM PROCEDURES WCH023TSHOT11080
Inspection Procedure 1: Communication with the PADT-II is not Possible (CVT-TCU

cannot be turned ON).
DOIMC023R11237
SYMPTOMS PROBABLE CAUSES

CVT-TCU cannot be turned ON. • Damaged wiring harness and connectors
• Malfunction of CVT-TCU

23 CVT
/ 186 SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
DOIMC023R11250

CVT 23
Inspection Procedure 2: Vehicle Creeps in the N Range. WCH023TSHOT11081

Engine torque is transferred to the drive shaft • Malfunction of the drive mode sensor.
in the N range, and the vehicle consequently • Malfunction of CVT assembly.
moves forward or rearward. • Damaged wiring harness and connectors.
• Malfunction of CVT-ECU.
DIAGNOSIS PROCEDURE
DOIMC023R11252
Inspection Procedure 3: Shock is experienced during N to D and/or N to R shifting

operation. WCH023TSHOT11082

Shock is experienced when the selector lever is • Abnormal line pressure
moved from the N to R range or from the N to D • Malfunction of CVT-ECU
range. • Malfunction of CVT assembly

23 CVT
DIAGNOSIS PROCEDURE
DOIMC023R11259
Inspection Procedure 4: Poor Acceleration or Incomplete Shifting Operation

WCH023TSHOT11083

Vehicle does not creep. Incomplete shifting • Malfunction of forward clutch
operation or extremely poor acceleration • Malfunction of torque converter
is observed. • Malfunction of CVT assembly
• Malfunction of valve body assembly
• Malfunction of CVT-ECU

CVT 23
DIAGNOSIS PROCEDURE
DOIMC023R11261

23 CVT
Inspection Procedure 5: Gears cannot be Changed in SAT Mode. WCH023TSHOT11084
DOIMC023R11231

Gears cannot be changed even when the SAT • Damaged wiring harness and connectors
mode button is switch. • SAT mode button malfunction
• Malfunction of CVT-ECU

CVT 23
DATA LIST / 191
DIAGNOSIS PROCEDURE
DOIMC023R11262
DATA LIST WCH023TSHOT11002

Item Standard Measure-
PADT-II display Check condition Remarks
no value ment unit
Engine runs at idle,
A/C OFF
1 Engine speed ± 850 rpm rpm Engine speeds at idle
Engine runs at idle,
A/C ON
-10 ~ 15 kgm (-
Engine torque - 100 ~ 150 Nm,
2 Vehicle being driven Nm Engine torque data
CAN -72.33 ~
108.49 ft.lbs) status; data by ECU
and data request by
-10 ~ 15 kgm (- TCU (approximately
Engine torque - 100 ~ 150 Nm, similar value)
3 Vehicle being driven Nm
TCU -72.33 ~
108.49 ft.lbs)
Ignition ON 0.0863
4 Throttle position % TPS Throttle position
Engine runs at idle 0.0431

23 CVT
/ 192 DATA LIST
89 °C (192.2 °F)
Engine coolant Engine coolant tem-
5 Engine runs at idle ~ 92 °C (197.6 °C
temp perature
°F)?
< 120 °C (248 Transmission coolant
6 Oil temperature Engine runs at idle °C
°F) temperature
Vehicle speed - out- 0 km/h (0 Value increases as
7 Ignition ON km/h
put speed mph) vehicle moves
Vehicle speed - 0 km/h (0 Value increases as
8 Ignition ON km/h
TCU mph) vehicle moves
0 km/h (0 Determine slipping
Average speed of
9 Vehicle being driven mph) to top km/h wheel between front
none driven wheels
speed and rear
Approximately similar
Primary pulley as the tachometer dis-
10 Vehicle being driven 0 ~ 7000 rpm rpm
speed play (when clutch is
closed)
Idling ratio of 2.43 X
Secondary pulley
11 Vehicle being driven — rpm Primary pulley speed
speed
value
Secondary pulley
speed value (X 5.76).
12 Output speed Vehicle being driven — rpm
Similar as vehicle
speed
13 Gear ratio Vehicle being driven 2.43 ~ 0.43 — Gear ratio operation
value (approximately
14 Target ratio Vehicle being driven 2.43 ~ 0.43 — similar value)
Timing measurement
for gear ratio to
15 Ratio gradient Vehicle being driven — 1/s
achieve target ratio
value
Gear shift position Clutch open when
16 Clutch slip (+ value) < 500 rpm rpm
at D/R value > 500 rpm
Invalid / Open / Filling
/ Applied / Creeping /
Gear shift position Take off/ Closed / Roll
17 Clutch status — —
at D/R out / Opening / Open-
ing SW / Opening
blocking wheels (BLR)
Unknown / First
Manual Gear / Second
Manual Gear / Third
Manual Gear / Fourth
Manual Gear / Fifth
18 Lever position — — —
Manual Gear / R (re-
verse) / Z1 / Z2 / Z3 / Z4
/ SAT; First Gear / SAT;
Second Gear /
SAT;Third Gear
Check the fault code
19 Number of DTC Ignition ON — —
if the value > 1

CVT 23
DATA LIST / 193
MIL physical output

20 MIL status Ignition ON OFF/ON —
indication
Brake pedal status
21 Brake status Ignition ON OFF/ON —
(Brake light switch)
22 Brake fault status Ignition ON OK/FAIL — Brake fault status
23 Shift lock Ignition ON OFF/ON — Shift lock status
Commanded clutch
24 Vehicle being driven 0 ~ 10 bar Clutch pressure opera-
pressure
tion (Approximately
Expected clutch similar value)
25 Vehicle being driven 0 ~ 10 bar
pressure
Commanded pulley
26 Vehicle being driven 0 ~ 50 bar Pulley 2 pressure oper-
2 pressure
ation (Approximately
Measured pulley 2 similar value)
27 Vehicle being driven 0 ~ 50 bar
pressure
Commanded cur-
28 rent of Pulley 1 Vehicle being driven 0 ~ 1000 mA Pulley 1 pressure regu-
Pressure Regulator lator operation (Ap-
Actual current of proximately similar
29 Pulley 1 Pressure Vehicle being driven 0 ~ 1000 mA value)
Regulator
Commanded cur-
30 rent of Pulley 2 Vehicle being driven 0 ~ 1000 mA Pulley 2 pressure regu-
Pressure Regulator lator operation (Ap-
31 Pulley 2 Pressure Vehicle being driven 0 ~ 1000 mA value)
Regulator
Commanded cur-
32 rent of Clutch Pres- Vehicle being driven 0 ~ 1000 mA Clutch pressure regu-
sure Regulator lator operation (Ap-
33 Clutch Pressure Vehicle being driven 0 ~ 1000 mA value)
Regulator
Ignition ON 11.6 V ~ 12.0 V
34 Battery voltage V Battery voltage level
Engine runs at idle 13.5 V
High side voltage 0 V
35 High side voltage Ignition ON 3.4 V V
when fault occur
Voltage during igni-
36 Ignition voltage Ignition ON 11.6 V ~ 12.0 V V
tion
Oil pressure sensor in-
37 5V sensor voltage Ignition ON 5.0 V V
put voltage
DMS and primary &
38 8.4V sensor voltage Ignition ON 8.4 V V secondary speed
sensor input voltage
39 Mileage Ignition ON — km Driven distance

23 CVT
/ 194 DATA LIST
No Error / Unstable
Engine torque / Air-
cond ON / Pressure
EOL Clutch Adapta-
40 Ignition ON — — too high / Engine
tion Error
speed too low / En-
gine speed too high /
Too many abortions

CVT 23
CHECK AT CVT TCU TERMINALS / 195
CHECK AT CVT TCU TERMINALS WCH023TSHOT11004
TERMINAL VOLTAGE
1. Connect a needle-nosed wire probe (Test harness: MB991223 or paper clip) to a voltmeter probe.
2. Insert the neddle-nosed wire probe into each of the CVT-TCU connector terminals from the side,
and measure the voltage while referring to the check chart.
NOTE
(1) Make sure the voltage measurement with the CVT-TCU connected.
(2) You may find it convenient to pull out the CVT-TCU in order to make it easier to reach con-
nector terminals.
3. If voltmeter shows any unordinary value from standard value, check the corresponding sensor,
actuator or related electrical wiring. Then repair or replace the corresponding.
4. After repair or replace, recheck with the voltmeter to reconfirm that the problem has been solved.
CAUTION
Short-circuiting the positive (+) probe between a connector terminal and earth could damage the
vehicle wiring, sensor, CVT-TCU or all of them. Be careful to prevent this!
DOIMC023R11071

23 CVT
/ 196 CHECK AT CVT TCU TERMINALS
Ter-
minal Description Check item Standard value
No.
1 Permanent supply
Always System voltage
2 (12V)
3
Ground Always System voltage
4
VHSD1 (High side
5 Always System voltage
actuator supply)
Ignition supply
6 Ignition switch: ON System voltage
(wake up)
8 CAN Low 1 — Approximately 1.908 V ± 0.2 V
9 CAN High 1 — Approximately 3.136 V ± 0.2 V
30 Speed & Drive
77 mode sensor sup- Ignition switch: ON 8.4 V
78 ply (8.4V)
32 Oil pressure sensor
Ignition switch: ON 4.5 V ± 0.5 V
74 supply (5V)
Drive mode sensor
33 Always 0.55 V ± 0.5 V
ground
Brake signal digit- Brake pedal pressed Battery voltage
34
al input Brake pedal released 0V
1. TCU disconnect
Ignition 2. ECU disconnect
35 DMS_D 4.5 V ± 0.5 V 4.35 kΩ
switch: ON 3. Pin 33 and pin
57
Transmission oil
38 Ignition switch: ON 4.5 V ± 0.5 V
temperature
41
64 Sensor ground Always 0.55 V ± 0.5 V
86
Shift lock output
48 Always Battery voltage
signal
Ignition
57 DMS_A Pin 33 and pin 57 4.5 V ± 0.5 V 4.35 kΩ
switch: ON
Ignition
58 DMS_B Pin 33 and pin 58 4.5 V ± 0.5 V 4.35 kΩ
switch: ON
Primary pulley
TCU discon-
61 speed signal Pin 77 and pin 61 5.3 MΩ
nect
(N_Prim)
Transmission out-
TCU discon-
63 put speed signal Pin 77 and pin 63 5.3 MΩ
nect
(N_AB)
71 Back light relay Ignition switch: ON System voltage

CVT 23
CHECK AT CVT TCU TERMINALS / 197
Ter-
minal Description Check item Standard value
No.
1. Pin 75 and pin
Secondary pres- Ignition 41 1. 40 Ω
75
sure (P_S2) switch: ON 2. Pin 75 and pin 2. 10 Ω
74
Stepped auto Ignition switch: ON 4.0 V ± 0.5 V
76
(SAT) mode Ignition switch: OFF 2.0 V ± 0.5 V
Ignition
79 DMS_C Pin 33 and pin 79 4.5 V ± 0.5 V 4.35 kΩ
switch: ON
Engine run- Engine at 900 rpm 30 Hz
ning
Engine speed sig- (Using a digit-
87
nal (N_MOT) al multimeter, Engine at 3000 rpm 100 Hz
switch to fre-
quency mode)
Ignition
89 EDS3 Pin 8 and pin 89 2.5 V ± 0.5 V 5.7 Ω
switch: ON
Ignition
switch: ON
Ignition
switch: ON
Ignition “P” or “N” gear
0V
switch: ON lever position
92 Start lock Other than “P” or
Ignition
“N” gear lever posi- 12.0 V
switch: ON
tion

23 CVT
/ 198 CHECK AT CVT CONNECTOR
CHECK AT CVT CONNECTOR WCH023TSHOT11006
TERMINAL ARRANGEMENT
TERMINAL ARRANGEMENT
DOIMC023R11111
Pin no Signal
1 Supply valves (VHS)
2 Primary pressure regulator (EDS1)
3 Secondary pressure regulator (EDS2)
4 Clutch pressure regulator (EDS3)
5 Oil temperature sensor
6 Drive mode sensor Ground (DMS_GND)
7 Ground
8 Supply (5.0 V)
9 Supply (8.4 V)
10 Secondary pressure sensor
11 Secondary speed sensor
12 Primary speed sensor
13 Drive mode sensor A (DMS_A)
14 Drive mode sensor B (DMS_B)

CVT 23
CHECK AT CVT CONNECTOR / 199
Pin no Signal
15 Drive mode sensor C (DMS_C)
16 Drive mode sensor D (DMS_D)

23 CVT
/ 200 CHECK AT CVT CONNECTOR
In most cases the error codes from the TCU will indicate if there is something wrong with one of the
electronic components inside the transmission. The following resistor measurements can be performed
to check if the electronic components are faulty or not. All measurements indicated here are performed
on the main harness connector of the transmission.
Item
Item Pin no. Resistance value
no.
20 °C (68 °F) 942 Ω
1 Oil temperature sensor Measure between pin 5 and pin 7
40 °C (104 °F) 1121 Ω
2 Primary speed sensor Measure between pin 9 and pin 12 24.3 MΩ
3 Secondary speed sensor Measure between pin 9 and pin 11 24.3 MΩ
Primary pressure regulator
6 Measure between pin 1 and pin 3 5.2 Ω
(EDS1)
Secondary pressure regulat-
or (EDS2)
Clutch pressure regulator
(EDS3)
4 Secondary pressure sensor Measure between pin 7 and pin 10 44.3 kΩ
DRIVE MODE SENSOR
Check the internal resistance between the different DMS pins.
Supply (8.4 V) DMS_A DMS_B DMS_C DMS_D

Supply (8.4 V) — 17.2 MΩ 17.2 MΩ 17.2 MΩ 17.2 MΩ
DMS_A 17.2 MΩ — 9.0 kΩ 9.0 kΩ 9.0 kΩ
DMS_B 17.2 MΩ 9.0 kΩ — 9.0 kΩ 9.0 kΩ
DMS_C 17.2 MΩ 9.0 kΩ 9.0 kΩ — 9.0 kΩ
DMS_D 17.2 MΩ 9.0 kΩ 9.0 kΩ 9.0 kΩ —
DMS_GND — 4.5 kΩ 4.5 kΩ 4.5 kΩ 4.5 kΩ
NOTE
Ranges of resistor values can differ in function of the accuracy of the measuring equipment.

CVT 23
ON-VEHICLE SERVICE / 201
ON-VEHICLE SERVICE WCH023SPROC11019
CVT COMPONENT LOCATION
DOIMC023R11145
Name Indication Location

CVT backup relay RB
A
Shifter relay RS
CVT Transmission control unit CVT TCU B
Stop lamp switch SL Switch C
Diagnosis connector DC D
SAT switch SAT E
Shift lock solenoid SL solenoid F
Primary speed sensor (Input speed sensor) PSS G
Secondary speed sensor (Output speed sensor) SSS
Oil temperature sensor OTS
Secondary pressure sensor SPS
Drive mode sensor (Position/Inhibitor sensor) DMS H
Primary pressure regulator solenoid EDS1
Secondary pressure regulator solenoid EDS2
Clutch pressure regulator solenoid EDS3

23 CVT
/ 202 ON-VEHICLE SERVICE
VIEW LOCATION

CVT 23
SHIFT CABLE ADJUSTMENT WCH023SPROC11018
This procedure describes how to install the shift

lever inside the car correctly with the transmis-
sion.
If this procedure is not done according to the
instruction, it is possible that the transmission is
in the correct state of ‘P-R-N-D’ for the driver to
select.
The dashboard will always indicates what the
state of the transmission, regardless what the
position of the shift lever is.
For a good cable adjustment the dashboard and
shift lever will indicate the same position ‘P-R-N-
D’.

23 CVT
1. Put the selector lever in ‘P’ position as shown

in the illustration when replacing new cable
or sevicing on the shift lever.
DOIMC023R11060
2. Lift up the vehicle and push the shift lever

manually in ‘P’ position (ensure the shift lever
is push until end) as shown in the illustration.
DOIMC023R11172
3. The ‘P’ position can be verified by checking

the indication on the dashboard.
DOIMC023R11159

CVT 23
4. Vehicle position on the lifter, turn both front

wheels at the same time till they are locked.
Now the transmission is locked in ‘P’ position.
CAUTION
During the vehicle on the lifter, straightly
not recommended to shift the selector lever
out of ‘P’ position to avoid from transmission
problem.
DOIMC023R11160
5. Before fix the eye of cable assy in the ad-

juster, insert the cable at the bracket to avoid
the cable from bending.
Follow this steps;
Step 1 • Insert Adjuster through eye of

Step 2 bracket cable assy
Step 3 • Insert washer
Step 4 • Insert snap pin
• Connect the cable to the shift
lever with screw and nut
DOIMC023R11161 CAUTION
Ensure the adjuster fit at the end
Step 5 of shift lever.
• Tighten the nut to the spe-
cified torque.
Specified torque:
1.0~1.5 kgm (10~15 Nm,
7.23~10.85 ft.lbs)
6. When tightening the nut, do not bend the
cable or the shift lever.
INSPECTION PROCEDURES
1. Move the selector lever to all position ‘P-R-
N-D’.
2. Ensure the selector lever inside the car is now
aligned with the transmission.
DOIMC023R11057

23 CVT
3. Visual check at the dashboard to ensure the

gear position is the same with the selector
lever.
CVT FLUID REFILL / CHECK WCH023SPROC11003
This procedure implies whenever the oil has

been drained from the transmission or transmis-
sion has been replaced with a new service
transmission.
Service transmissions are not pre-filled and need
to be filled up after installing in the vehicle with
DOIMC023R11173
approximately 4.15 lit (4.37 U.S.qts, 3.6 Imp.qts)
± 0.05 lit (0.053 U.S.qts, 0.043 Imp.qts) of ESSO
EZL799.
After the initial fill, the correct way to check the
oil level is listed below:
1. Start the engine and stay at idle for at least
10 seconds (note: air circulating through the
system may be heard on initial start-up, this
is a normal operating condition).
DOIMC023R11055
2. Apply the brake pedal.
DOIMC023R11066

CVT 23
3. Shift selector lever into each position (P-R-N-

D) and allow the gear to rest in each of its
position for 5 seconds before progressing to
the next position.
DOIMC023R11057
4. Move the selector lever into ‘D’ position.
DOIMC023R11058
5. Release the brake pedal.
DOIMC023R11063
6. Apply a little throttle to minimum 60 km/h

(the engine speed must not be higher than
2500 rpm).
DOIMC023R11064

23 CVT
7. Release the throttle and slightly break to a

standstill (all the noises by air circulating in
the system during the first up shifting should
be gone).
8. To increase the oil temperature, drive care-
fully around (increase the vehicle speed at
least 3 times between 0 km/h and 60 km/h),
for at least 5 minutes or until the temperat-
ure of the transmission has reached approx-
imately 60 °C (140 °F).
9. Place the car on a flat ground or ramp.
DOIMC023R11065
10. Apply the brake pedal.

11. Wait two seconds.
DOIMC023R11066
12. Move the selector lever into ‘R’ position.

13. Wait 10 seconds.
DOIMC023R11059
14. Move the selector lever into ‘P’ position.

Keep the engine running idle.
DOIMC023R11060

CVT 23
15. Remove the under cover LH.
DOIMC032L08012
16. Remove the oil level plug.
DOIMC023R11061
17. Make sure minimum 0.2 lit (0.21 U.S.qts, 0.17

Imp.qts) of oil flows out of the oil level tube
after removing the level plug (otherwise the
initial amount of oil wasn’t sufficient).
If not, add another 0.5 litre extra and redo
complete procedure.
Wait a few minutes until the oil that comes
out of the level begins to drip.
DOIMC023R11062
18. Refit the oil level plug with sealing ring.

Specified torque:
1.8~2.4 kgm (18~24 Nm, 13.02~17.36 ft.lbs)
DOIMC023R11061

23 CVT
19. Switch off the engine.
DOIMC023R11056
CVT FLUID REPLACEMENT WCH023SPROC11011
DOIMC032L08013
2. Remove the drain plug and drain the trans-

mission oil.
Install back the drain plug and torque to the
specified torque.
Specified torque:
0.72 ft.lbs).
DOIMC023R11120

CVT 23
3. Remove the oil filling plug on top of the

transmission.
DOIMC023R11067
4. Fill the transmission oil with exactly 4.15 lit

(4.37 U.S.qts, 3.6 Imp.qts) ± 0.05 lit (0.053
U.S.qts, 0.043 Imp.qts) .
Transmission oil:
ESSO EZL799
DOIMC023R11068
5. Refit the oil filling plug together with the

sealing ring.
Specified torque:
1.8~2.4 kgm (18~24 Nm, 13.02~17.36 ft.lbs).
6. Detail procedure for check the transmission

oil, refer to 23/206 .
OIL LEVEL CHECK WCH023SPROC11004
If the initial fill was done properly, the oil level

will be at a correct level (“level-plug” level).
DOIMC023R11067
Due to tolerances (such as: new transmissions are
delivered with a residual oil volume and initial
fill tolerances) the tolerance on the correct
“level-plug”-level will be ± 0.165 lit (0.17 U.S.qts,
0.14 Imp.qts).
In case of an oil level check proceed as follow:

23 CVT
1. Remove the oil filling plug on top of the

transmission.
DOIMC023R11067
2. Fill the transmission with exactly 0.5 lit (0.53

U.S.qts, 0.43 Imp.qts) ± 0.05 lit (0.053 U.S.qts,
0.043 Imp.qts).
DOIMC023R11068
3. Refit the oil filling plug together with the

sealing ring.
Specified torque:
1.8~2.4 kgm (18~24 Nm, 13.02~17.36 ft.lbs)
4. To increase the oil temperature, drive care-

fully around for at least 5 minutes or until
the temperature of the transmission has
reached approximately 60 °C (140 °F).
5. Place the car on a flat ground.
DOIMC023R11067
6. Apply the foot brake.

7. Wait two seconds.
DOIMC023R11066

CVT 23
8. Move the selector lever into ‘P’ position.

9. Keep the engine running idle.
DOIMC023R11060
10. Remove the oil level plug (while engine

running idle).
DOIMC023R11061
11. Collect the drained oil (min 0.335 lit (0.35

U.S.qts, 0.29 Imp.qts) and max 0.665 lit (0.7
U.S.qts, 0.58 Imp.qts))
11.1 Minimum 0.335 lit (0.35 U.S.qts, 0.29
Imp.qts) ( 0.5 ADDED OIL - 0.165 toler-
ances = 0.335 Litre ) oil will drain out
off the transmission.
If the collected amount is less: the initial
level was too low
11.2 Maximum 0.665 lit (0.7 U.S.qts, 0.58
Imp.qts) ( 0.5 ADDED OIL + 0.165 tol-
erances = 0.665 Litre ) oil will drain out
DOIMC023R11062 off the transmission.
If the collected amount is more: the
initial level was too high
* The mentioned values are valid for
exactly 60 deg.

23 CVT
12. Refit the oil level plug with sealing ring.

Specified torque:
1.8~2.4 kgm (18~24 Nm, 13.02~17.36 ft.lbs)
DOIMC023R11061
13. Switch off the engine.
DIFFERENTIAL SEAL WCH023SPROC11005
In case of damage/leakage on seal or half shaft.

DIFFERENTIAL SEAL LH/RH REMOVAL
1. Drain transmission oil (Detail procedure refer
to 23/206 ).
2. Remove the tyre LH/RH detail procedures
refer to GROUP 031 – Wheel and tyre (PUB.
NO. RDWE-08MA010).
3. Remove the tie rod end connection detail
DOIMC023R11056
procedures refer to GROUP 37A – Steering
4. Remove the lover arm ball joint connection
NO. RDWE-08MA010).

CVT 23
5. Insert a bar between transmission case and

the drive shaft in order to remove the drive
shaft.
DOIMC023R11039
6. Use a big screw driver to pinch out the seal.

Be careful not to put screwdriver in too deep,
otherwise the housing can be damaged by
the tip of the screwdriver.
DOIMC023R11040
DIFFERENTIAL SEAL LH/RH INSTALLATION

1. Take a new seal and put it in the transmission
housing, place the special tool P480143 on
the seal and use a rubber hammer to knock
oil seal into the transmission housing. Ham-
mer it all the way in untill no further is pos-
sible.
DOIMC023R11041

23 CVT
2. Locate the special tool EZT 0042 at the differ-

ential seal as shown in the illustration.
DOIMC023R11042

the transmission hole.
NOTE
4. Install the lover arm ball joint connection
NO. RDWE-08MA010).
DOIMC023R11043
5. Install the tie rod end connection detail pro-
cedures refer to GROUP 37A – Steering (PUB.
NO. RDWE-08MA010).
6. Install the tyre LH/RH detail procedures refer
to GROUP 031 – Wheel and tyre (PUB. NO.
RDWE-08MA010).
7. Refill transmission oil (Detail procedure refer
to 23/206 ).
PRIMARY COVER WCH023SPROC11006
In case of leakage on primary cover.

PRIMARY COVER REMOVAL
DOIMC032L08013

CVT 23

mission oil approx 1 litre.
Install back the drain plug and torque to the
specified torque.
Specified torque:
0.72 ft.lbs).
DOIMC023R11120
3. Remove the primary cover bolts and clips.
DOIMC023R11045
4. Use a screw driver to lift out the primary

cover. Cover the tip of screw driver by cloth
to protect the transmission case from dam-
age.
DOIMC023R11046

23 CVT
5. Remove the big O-ring.
DOIMC023R11047
PRIMARY COVER INSTALLATION

1. Take a new big O-ring and assemble it to the
transmission housing.
NOTE
(1) Lubricate new a big O-ring by transmis-
sion oil before installation.
(2) Install a big O-ring at the lower groove
first.
DOIMC023R11048
2. Install the primary cover to the transmission

housing.
Knock the primary cover by hand.
NOTE
In case of damaged cover, take a new
primary cover.
DOIMC023R11049
3. Fix the clips and tighten the bolts to the

specified torque.
Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.25 kgm (2.5
Nm, 1.81 ft.lbs).
DOIMC023R11045

CVT 23
4. Remove the refill plug, refill transmission oil

approx 1 litre as shown in the illustration.
SECONDARY COVER WCH023SPROC11007
In case of the secondary cover damage or leak-

age.
DOIMC023R11050
SECONDARY COVER REMOVAL

1. Remove the secondary cover screws.
DOIMC023R11051
2. Remove the secondary cover.
DOIMC023R11052

23 CVT
3. Use the small screw driver to remove the O-

rings and center sealing ring.
DOIMC023R11053
SECONDARY COVER INSTALLATION

1. Replace a new O-ring and center sealing ring
and assemble it to the secondary cover.
NOTE
Lubricate new O-rings by transmission oil
first before installation.
DOIMC023R11054
2. Install the secondary cover.

NOTE
In case of damaged cover, take a new second-
ary cover.
DOIMC023R11052
3. Tighten the secondary cover screws to the

specified torque.
Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.09 kgm (0.9
Nm, 0.65 ft.lbs).
OIL PUMP WCH023SPROC11009
In case the transmission pressure is too low or

the driver feel shocks or abnormal driving beha-
viour, there are two main possibility parts can
DOIMC023R11051
cause this problem, hydraulic unit or oil pump.

CVT 23
Also analyze the P-code and follow actions on

specific P-code to replace either hydraulic unit
or pump.
In most of cases it is unclear which one the
problem causes so it can be replace one by one
and check if the problem is solve.
OIL PUMP REMOVAL
1. Remove the primary cover (Detail procedure
for removal and installation of primary cover
refer to 23/216 ).
2. Remove the oil pump bolts.
DOIMC023R11080
3. Use the special tool Mot. 1335 to lift out the

oil pump.
DOIMC023R11081
4. Remove the oil pump by hand.

CAUTION
Be careful, do not drop oil pump.
DOIMC023R11082

23 CVT
5. Remove the belle-ville washer.
DOIMC023R11083
OIL PUMP INSTALLATION

1. Install the belle-ville washer.
CAUTION
Leave it in its correct position which is
biggest diameter facing the oil pump.
DOIMC023R11083
2. Install the new oil pump and new O-rings

properly.
CAUTION
Ensure the oil pump O-rings not protrude.
DOIMC023R11082
3. Tighten the oil pump bolts to the specified

torque.
Specified torque:
0.72 ft.lbs).
CAUTION
Torque the bolts as sequence as shown in
the illustration.
4. Install the primary cover (Detail procedure
refer to 23/216 ).
DOIMC023R11084

CVT 23
PRIMARY BALL BEARING WCH023SPROC11010
In case of worn out primary ball bearing.

A worn out primary ball bearing will produce a
big noise for which of the frequency is depend
on engine speed.
This can be easily check by driving at a constant
speed and shift to sport mode.
The engine rpm will go up and if the noise fre-
quency also goes up, then there is a big possibil-
ity that you have a worn out primary ball bear-
ing.
PRIMARY BALL BEARING REMOVAL
1. Remove the primary cover (Detail procedure
refer to 23/216 ).
2. Remove the oil pump (Detail procedure for
removal and installation of primary cover
refer to 23/220 ).
3. To remove the primary nut, ensure to do a
marking on it permanently.
DOIMC023R11085
4. Use socket with the size of 46 mm (1.81 in)

by using high spec of an air impact wrench
due to remove the primary nut.
DOIMC023R11086

23 CVT
5. Lever out the seal of the primary ball bearing

using a small screw driver.
DOIMC023R11087
6. Use the special tool MD998348 and

MB991202 to lift out the primary ball bear-
ing.
DOIMC023R11088
PRIMARY BALL BEARING INSTALLATION

1. Fix the ball bearing to the ball bearing
housing by hand.
DOIMC023R11089
2. Use the special tools P480137 and MD998350

to install the primary ball bearing.
DOIMC023R11090

CVT 23
3. Fix the primary nut by hand.
DOIMC023R11091
4. Using air impact tighten primary nut to the

specified torque.
Specified torque:
19.75 kgm (197.5 Nm, 142.85 ft.lbs) ± 1.75
kgm (17.5 Nm, 12.66 ft.lbs).
CAUTION
Ensure the marking is at it original position.
5. Install the oil pump (Detail procedure for
removal and installation of primary cover
refer to 23/220 ).
6. Install the primary cover (Detail procedure
DOIMC023R11086 for removal and installation of primary cover
refer to 23/216 ).
OIL PAN AND OIL FILTER WCH023SPROC11012
In case of oil pan damage and or leak.

23 CVT
OIL PAN AND OIL FILTER REMOVAL

mission oil.
DOIMC023R11120
2. Remove the oil pan bolts.
DOIMC023R11092
3. Remove the oil pan and gasket.

CAUTION
(1) Even though the transmission oil has
been drained out, there will be some oil
remaining in the oil pan.
(2) Be careful not to splash the transmission
oil.
DOIMC023R11093

CVT 23
4. Remove the oil filter by pulling it gently.
DOIMC023R11094
OIL PAN AND OIL FILTER INSTALLATION

1. Before install the oil filter, lubricate the O-
ring with clean ESSO EZL799.
DOIMC023R11095
2. Clean the magnet and surface of oil pan.
DOIMC023R11096
3. Install oil pan, gasket and filter together to

the transmission (center hole of oil filter
should match center bolt of hydraulic unit).
DOIMC023R11097

23 CVT
4. Tighten oil pan bolts to the specified torque.

Specified torque:
0.72 ft.lbs).
CAUTION
the illustration.
5. Fill transmission oil according instruction,
(Detail procedure for fill and check transmis-
sion oil refer to 23/206 ).
DRIVE MODE SENSOR WCH023SPROC11013
In case of faulty drive mode sensor.

Dedicated error code should indicate problem
with drive mode sensor.
Replace drive mode sensor when error code ac-
tion indicates it.
DRIVE MODE SENSOR REMOVAL
1. Remove the oil pan and oil filter, (Detail
procedure for remove the oil pan and oil fil-
ter refer to 23/225 ).
DOIMC023R11098
2. Push the shift lever manually is in ‘P’ position.
DOIMC023R11101
3. Remove the 2 bolts of the drive mode sensor.
DOIMC023R11102

CVT 23
4. Push down the sensor to remove the pin

from the metal slide.
DOIMC023R11103
5. Use small screwdriver to unlock the gray lock

button of the drive mode sensor connector
by pushing it forward.
DOIMC023R11104
DRIVE MODE SENSOR INSTALLATION

1. Take a new drive mode sensor, connect the
connector to the main cable harness and lock
it by pushing the gray lock button.
DOIMC023R11105
2. Place drive mode sensor against the metal

slide, with the guiding pin on the back of
the sensor locked in the metal slide groove.
DOIMC023R11103

23 CVT
3. Align the drive mode sensor so the screw

holes lign up, tighten drive mode sensor bolt
Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.095 kgm
(0.95 Nm, 0.69 ft.lbs).
4. Install the oil pan and oil filter, (Detail pro-

cedure for install the oil pan and oil filter
refer to 23/225 ).
HYDRAULIC UNIT WCH023SPROC11014

DOIMC023R11102
In case there is a problem with the transmission
pressure or the driver feel shocks or abnormal
driving behavior, two main parts can cause this
problem, hydraulic unit or oil pump.
Also analyze the P-code and follow actions on
specific P-code to replace either hydraulic unit
or pump.
In most of cases it is unclear which one the
problem causes so one by one can be replaced
and see if the problem is solved.
HYDRAULIC UNIT REMOVAL
2. Remove the drive mode sensor, (Detail pro-
cedure for remove the drive mode sensor
refer to 23/228 ).
3. Remove the 20 pieces bolt of the hydraulic
unit.
DOIMC023R11106

CVT 23
4. Take out the hydraulic unit and disconnect

the 4 connectors.
DOIMC023R11107
HYDRAULIC UNIT INSTALLATION

1. Take a new hydraulic unit and connect the
4 connectors.
CAUTION
No mistake can be made due to the length
of the cables.
DOIMC023R11107
2. Install the hydraulic unit in place.

CAUTION
Make sure that the hydraulic unit metal slide
fits in the pin of the rooster cam plate.
DOIMC023R11108

23 CVT
3. Place the center screw and hand tighten it

and fix the special tool P480142 on the top
left screw hole and screw it in.
DOIMC023R11109
4. Place all screws of hydraulic unit, except the

upper left one, remove the special tool
P480142, and tighten upper left bolt.
Tighten the bolt to the specified torque.
Specified torque:
0.72 ft.lbs).
CAUTION
the illustration.
5. Install the drive mode sensor, (Detail proced-
ure for remove the drive mode sensor refer
to 23/228 ).
refer to 23/225 ).
SECONDARY SPEED SENSOR AND

BRACKET WCH023SPROC11015
In case indicate by actions from the error code

list.
SECONDARY SPEED SENSOR AND BRACKET
REMOVAL
DOIMC023R11110 1. Remove the oil pan and oil filter, (Detail
refer to 23/228 ).
3. Remove the hydraulic unit, (Detail procedure
for remove the hydraulic unit refer to 23/230
).

CVT 23
4. Remove the bolt of the bracket secondary

speed sensor.
DOIMC023R11156
5. Use plier to remove the secondary speed

sensor.
DOIMC023R11157
SECONDARY SPEED SENSOR AND BRACKET

INSTALLATION
1. Take a new secondary speed sensor, connect
wire and slide bracket output sensor back in
the selector shaft.
DOIMC023R11158
2. Tighten the bracket secondary speed sensor

bolt to the specified torque.
Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.095 kgm
(0.95 Nm, 0.69 ft.lbs).
3. Install the hydraulic unit, (Detail procedure

for install the hydraulic unit refer to 23/230 ).
ure for remove the drive mode sensor refer
to 23/228 ).
DOIMC023R11156

23 CVT

refer to 23/225 ).
PRIMARY SPEED SENSOR WCH023SPROC11016

list.
PRIMARY SPEED SENSOR REMOVAL
1. Remove the primary cover, (Detail procedure
for remove the primary cover refer to 23/216
).
2. Use plier to remove the primary speed sensor
connector.
DOIMC023R11112
3. Remove the bolt and take out the primary

speed sensor.
DOIMC023R11113
PRIMARY SPEED SENSOR INSTALLATION

1. Install the primary speed sensor and tighten
the bolt to the specified torque.
Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.095 kgm
(0.95 Nm, 0.69 ft.lbs).
DOIMC023R11113

CVT 23
2. Install the primary speed sensor connector.

3. Install the primary cover, (Detail procedure
for install the primary cover refer to 23/216 ).
MAIN CONNECTOR AND INTERNAL CABLE

HARNESS WCH023SPROC11017

list.
HARNESS REMOVAL
DOIMC023R11114
refer to 23/228 ).
3. Remove the hydraulic unit, (Detail procedure
for remove the hydraulic unit refer to 23/230
).
4. Disconnect the output speed sensor, (Detail
procedure for disconnect the output speed
sensor refer to 23/232 ).
5. Remove the primary cover, (Detail procedure
for remove the primary cover refer to 23/216
).
6. Disconnect the primary speed sensor connect-
or, (Detail procedure for disconnect the
primary speed sensor refer to 23/234 ).
7. Disconnect the car cable harness connector
from the main connector and internal cable
harness on the transmission.
8. Using plier remove the main connector clip.
DOIMC023R11115

23 CVT
9. Press the main connector and internal cable

harness with finger into the transmission.
DOIMC023R11116
10. Remove the main connector and internal

cable harness.
DOIMC023R11117

HARNESS INSTALLATION
1. Take a new main connector and internal
cable harness, ensure the connector oil ring
seat at it position as shown in the illustration.
DOINT23CR11037

CVT 23
2. Install the main connector and internal cable

harness properly.
CAUTION
Ensure the connect slot lock at transmission
case.
DOIMC023R11118
3. Install the clip main connector properly.

4. Reconnect the primary speed sensor connect-
or, (Detail procedure for reconnect the
primary speed sensor refer to 23/234 ).
5. Reconnect the output speed sensor, (Detail
procedure for reconnect the output speed
sensor refer to 23/232 ).
6. Install the primary cover, (Detail procedure
for install the primary cover refer to 23/216 ).
7. Install the hydraulic unit, (Detail procedure
for install the hydraulic unit refer to 23/230 ).
DOIMC023R11119 ure for remove the drive mode sensor refer
to 23/228 ).
refer to 23/225 ).

23 CVT
/ 238 TCU, ECU AND BRACKET
TCU, ECU AND BRACKET WCH023SASSY11004
DOIMC023R11174

• Floor Console removal and installation (Refer to Pub. No. RDWE-08MA010, GROUP 52A — Floor
Console).
CAUTION
(1) Before remove the TCU or ECU wiring harness connectors, ensure disconnect the battery terminal
first.
(2) After install the TCU or ECU, ensure connect the TCU or ECU wiring harness connectors properly.
TCU removal steps:
2. TCU wiring harness connector.
3. TCU assembly
ECU removal steps:
4. ECU assembly
Bracket assembly removal steps:
2. TCU wiring harness connector.
5. Bracket assembly

CVT 23
TCU, ECU AND BRACKET / 239
FLOOR CONSOLE REMOVAL

NOTE:
Detail service procedure for removal floor con-
sole, refer to GROUP 52A – Floor console (PUB.
NO. RDWE-08MA010).
TCU REMOVAL
CAUTION
Before remove the TCU wiring harness connect-
or, ensure disconnect the battery terminal first.
1. Use the small screw driver to push the ECU
connector lock.
DOIMC023R11175

or).
DOIMC023R11176

connector lock.
DOIMC023R11183

23 CVT

or).
DOIMC023R11184
5. Use the big screw driver to pry out the TCU

connector lock lever.
DOIMC023R11177
6. Disconnect the TCU connector.
DOIMC023R11178
7. From the right hand side, push out the TCU.
DOIMC023R11179

CVT 23
TCU, ECU AND BRACKET / 241
8. Remove the TCU from the bracket.
DOIMC023R11180
ECU REMOVAL
CAUTION
Before remove the ECU wiring harness connect-
ors, ensure disconnect the battery terminal first.
connector lock.
DOIMC023R11175

or).
DOIMC023R11176

connector lock.
DOIMC023R11183

23 CVT

or).
DOIMC023R11184
5. Remove the ECU mounting nuts (4 pieces).
DOIMC023R11185
6. Remove the ECU from the bracket.

TCU INSTALLATION
Reverse order the removal procedure to install
back the TCU.
CAUTION
After install the TCU , ensure the connector fits
ECU INSTALLATION
DOIMC023R11186
back the ECU.
CAUTION
After install the ECU , ensure the connectors fits
FLOOR CONSOLE INSTALLATION

NOTE:
Detail service procedure for install the floor
console, refer to GROUP 52A – Floor console

CVT 23
CVT FLUID COOLER / 243
CVT FLUID COOLER WCH023SASSY11003
DOIMC023R11275

• Front bumper removal and installation (Refer to Pub. NO. RDWE–08MA010–04, GROUP 51 - Front
Bumper.)
• CVT fluid refilling (Refer to 23/206 .)
CVT fluid cooler removal steps
1. CVT fluid cooler hose assembly
2. CVT fluid cooler assembly

23 CVT
/ 244 CVT FLUID COOLER
NOTE
(1) Detail for removal and installation procedure
of front bumper refer to the GROUP 051-
Front bumper, Pub. NO. RDWE–08MA010–04.
(2) Detail procedure for CVT fluid refill and
check refer to 23/206 .
CVT FLUID COOLER ASSY REMOVAL

1. Remove the front bumper, refer to the
GROUP 051-Front bumper, Pub. NO. RD-
WE–08MA010–04.
DOIMC023R11074
2. Press and release the CVT fluid cooler hose

connections (Transmission side).
DOIMC023R11276
3. Press and release the CVT fluid cooler hose

connections (CVT fluid cooler side).
DOIMC023R11277

CVT 23
CVT FLUID COOLER / 245
4. Remove the bracket CVT fluid cooler upper

nuts.
DOIMC023R11278
5. Pull down the CVT fluid cooler assy (with

bracket oil cooler lower).
CAUTION
Be careful, do not drop the CVT fluid cooler
assy.
DOIMC023R11279

CVT FLUID COOLER ASSY INSTALLATION
1. Reverse order the removal procedure to in-
stall back CVT fluid cooler assy.
2. Fit the bolt weld with rubber cushion first
into the sub frame hole.
CAUTION
(1) Ensure CVT fluid cooler hose install at
right position.
(2) Ensure CVT fluid cooler hose fit firmly
when installed.
(3) Ensure to inspect the CVT fluid volume
is at the specified level.
DOIMC023R11281

23 CVT
/ 246 CVT FLUID COOLER
3. Detail procedure for refilling the CVT fluid

and level check, refer to 23/206 .
DOIMC023R11068

CVT 23
TRANSMISSION CONTROL WCH023SASSY11001
DOIMC023R11011
Pre-removal and Post-Installation Operation

• Floor Console removal and installation (Refer to GROUP 52A - Floor Console, Pub. NO. RD-
WE–08MA010)
CAUTION:
(1) Be careful not to subject the SRS-ECU to any shocks during removal and installation of the
transmission control cable and selector lever assembly.
(2) Turn “ON” ignition switch and apply brake pedal before move the selector lever.
(3) After install the Cable assy CVT and selector lever assy, ensure checking the operation of selector
lever.

23 CVT
Cable assy CVT removal steps

1. Snap pin (Side lever selector).
2. Cable assy CVT connection (Side lever selector).
3. Nut
4. Snap pin (Transmission side).
5. Washer
6. Cable assy CVT connection (Transmission side).
7. Nut
8. Adjuster
9. Cable assembly CVT
Selector lever assy removal steps
1. Snap pin (Side lever selector).
2. Cable assembly CVT connection (Side lever selector).
10. Lever assy selector.
T1 : 1.0~1.5 kgm (10~15 Nm, 7.23~10.85 ft.lbs)

CVT 23
SELECTOR LEVER ASSY

DISASSEMBLY AND REASSEMBLY
DOIMC023R11012
Componant list:
1. Lever assy base 9. Shift lock release spring
2. Mounting damper 10. Outer panel
3. Collar 11. Shift lock release cover
4. Wire harness assy 12. Position plate
5. Shift lock lever 13. Knob
6. Inner panel 14. SAT switch assy
7. Plate slide shift 15. Solenoid
8. Shift lock release button
T1 : 0.8~1.0 kgm (8~10 Nm, 5.79~7.23 ft.lbs)
T2 : 0.3~0.5 kgm (3~5 Nm, 2.17~3.62 ft.lbs)
T3 : 0.1~0.3 kgm (1~3 Nm, 0.72~2.17 ft.lbs)

23 CVT
NOTE
Detail for removal and installation procedure of
the floor console refer to the GROUP 52A-Floor
console Pub. NO. RDWE–08MA010.
CAUTION
(1) Be careful not to subject the SRS-ECU to any
shocks during removal and installation of
the cable assy CVT.
(2) Turn “ON” ignition switch and apply brake
pedal before move the gear lever.
CABLE ASSY CVT REMOVAL

1. Use the screw driver to remove the snap pin
from selector lever assy.
DOIMC023R11001
2. Use the plier to release the cable assy CVT

lock from selector lever assy.
DOIMC023R11002
3. Lift up the vehicle, release the cable assy CVT

from the cable support.
DOIMC023R11003

CVT 23
4. Remove the heat protector shield bolts and

move the heat protector shield backward as
DOIMC023R11004
5. Remove the retainer nuts as shown in the il-

lustration.
DOIMC023R11005

lock.
DOIMC023R11006

23 CVT
7. Use the plier to remove the snap pin and

washer from the transmission lever selector
shaft.
DOIMC023R11007
8. Push out the cable assy CVT connection from

the transmission lever selector shaft.
DOIMC023R11008
9. Pull out the cable assy CVT from the floor

hole.
DOIMC023R11009
SELECTOR LEVER ASSY REMOVAL

1. Use the screw driver to remove the snap pin
from selector lever assembly.
DOIMC023R11001

CVT 23

lock from selector lever assembly.
DOIMC023R11002
3. Remove the selector lever nuts.
DOIMC023R11036
4. Disconnect selector lever from the connector

harness.
DOIMC023R11037
5. Remove the selector lever assy.

CAUTION
After install the cable assy CVT and selector lever
assembly, ensure to check the operation of se-
lector lever.
CABLE ASSY CVT INSTALLATION

back cable assy CVT.
DOIMC023R11038

23 CVT
SELECTOR LEVER ASSY INSTALLATION

back selector lever assy.

CVT 23
TRANSMISSION ASSEMBLY WCH023SASSY11002
DOIMC023R11128

• Air cleaner removal and installation (Refer to GROUP 015 – Air cleaner).
• Battery and battery tray removal.
• Transmission oil draining (Refer to 23/210 ).
• Exhaust front removal and installation (Refer to Pub. No. RDWE-08MA010, GROUP 015 — Exhaust
front).
• Catalytic converter removal and installation (Refer to Pub. No. RDWE-08MA010, GROUP 015 —
Intake and exhaust).
• Front sub-frame removal and installation (Refer to Pub. No. RDWE-08MA010, GROUP 032 —
Front sub-frame).
• Drive shaft removal and installation (Refer to 23/214 ).
NOTE:
(1) Before remove the transmission, ensure disconnect the engine wiring harness connectors first.
(2) After install the transmission, ensure connect the engine wiring harness connectors properly.
(3) After install the transmission, ensure to check the operation of the shift lever.
(4) After install the transmission, ensure to check the operation of the meter and gauge.
(5) Support the radiator assy by wire.
(6) Support the power steering assembly by wire.

23 CVT
Removal steps:
1. Battery terminal (+/-).
2. CVT main harness connector.
3. CVT fluid cooler hose connection.
DOIMC023R11129
Non-reusable parts
Removal steps 11. Transmission assembly lower part coupling
4. Snap pin bolts (5 pieces)
5. Washer 12. Starter coupling bolts (2 pieces)
6. Cable assy CVT connection 13. Transmission assembly upper part coupling
7. Nut bolt (3 pieces)
8. Adjuster 14. Transmission mounting bracket assy
9. Drive shaft RH 15. Transmission mounting bracket assy support
10. Drive shaft LH 16. Transmission assembly
T1 : 10.0 kgm (100 Nm, 72.33 ft.lbs) ± 1.0 kgm (10 T5 : 2.8~3.2 kgm (28~32 Nm, 20.25~23.15 ft.lbs)
Nm, 7.23 ft.lbs) T6 : 3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.3 kgm (3 Nm,
5.06 ft.lbs) T7 : 5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.5 kgm (5 Nm,
T3 : 4.8~5.2 kgm (48~52 Nm, 34.72~37.61 ft.lbs) 3.62 ft.lbs)
T4 : 3.5~4.5 kgm (35~45 Nm, 25.32~32.55 ft.lbs)

CVT 23
CAUTION:
Mounting locations marked by * should be provisionally tightened and then fully tightened when

23 CVT
AIR-CLEANER REMOVAL
NOTE:
Detail of the removal service procedure for the
Air-cleaner, refer to GROUP 015 – Air-cleaner
BATTERY AND BATTERY TRAY REMOVAL

NOTE:
battery and battery tray, refer to GROUP 054
CVT CABLE ASSY REMOVAL

NOTE:
CVT cable assy, refer to 23/250 .
FRONT SUB FRAME REMOVAL

NOTE:
front sub frame, refer to GROUP 032 – Front sub
frame (PUB. NO. RDWE-08MA010).
TRANSMISSION ASSEMBLY REMOVAL

1. Remove the CVT main connector.
DOIMC023R11014
2. Remove the all CVT harness brackets at the

transmission.
DOIMC023R11015

CVT 23
3. Remove the all CVT harness clips at the

transmission.
DOIMC023R11016
4. Remove the transmission cooler hoses.
DOIMC023R11017
5. Lift up the vehicle, remove the under cover

LH.
DOIMC032L08012

23 CVT
6. Use the Allen key to remove the drain plug

to drain the transmission oil.
DOIMC023R11120

the drive shaft.
CAUTION
(1) Be careful do not damage the transmis-
sion case.
cause it will damage the transmission oil
seal.
DOIMC023R11039

CVT 23
8. Hang the drive shaft with a wire cord for

easier to remove the transmission.
DOIMC023R11026
9. Remove the transmission lower coupling

bolts.
NOTE
Remove 4 pieces of bolts but let 1 piece of
bolt remain loosely intect.
DOIMC023R11027
10. Remove the starter lower mounting bolt.
DOIMC023R11028

23 CVT
11. Remove the earth upper starter mounting

bolt.
DOIMC023R11018
12. Remove the transmission upper coupling

bolts.
NOTE
Remove 2 pieces of bolts but let 1 piece of
bolt remain loosely intect.
DOIMC023R11019
13. Disconnect the oxygen sensor connector.
DOIMC023R11020
14. Remove the exhaust manifold heat protector.
DOIMC023R11021

CVT 23
15. Remove the catalytic converter upper

mounting nuts.
DOIMC023R11022
16. Lift up the vehicle and remove the catalytic

converter lower mounting bolts.
DOIMC023R11023
17. Remove the catalytic converter assembly.
DOIMC023R11024

23 CVT
18. Set the engine lifter MZ2033827 to the

vehicle in order to support the engine as-
sembly.
NOTE
Locate engine hanger to the new position
as shown in the illustration (to get a center
point balancing of the engine).
DOIMC023R11013
19. Remove the transmission mounting bracket

assy.
DOIMC023R11029

assy support.
DOIMC023R11030

CVT 23
21. Set the garage crane to the vehicle in order

to support transmission assembly.
DOIMC023R11031
22. Remove the transmission lower coupling bolt

by hand.
DOIMC023R11070
23. Remove the transmission upper coupling bolt

by hand.
DOIMC023R11032

23 CVT
24. Using the screw driver to pry out the trans-

mission.
DOIMC023R11033
25. Slowly lift down the transmission assy and

remove the transmission from the vehicle.
CAUTION
Be careful do not damage the transmission case.
TRANSMISSION ASSEMBLY INSTALLATION
1. Reverse order the procedure of removal to
install back transmission assembly.
2. Detail procedure for refilling the CVT fluid,
refer to 23/210 .
DOIMC023R11034

INSTALLATION
Install the transmission mounting stopper by
ensuring the arrow is 'UP' direction as shown in
the illustration.
CAUTION:
Please ensure the transmission mounting stopper
is properly fitted and installed at it position be-
fore tightening the transmission insulator
mounting bolt.
DOIMC023R11035
FRONT SUB FRAME INSTALLATION
NOTE:
Detail of installation service procedure for the
front sub frame, refer to GROUP 032 – Front sub
frame (PUB. NO. RDWE-08MA010).
CVT CABLE ASSY REMOVAL

NOTE:
CVT cable assy, refer to 23/250 .

CVT 23
BATTERY AND BATTERY TRAY

INSTALLATION
NOTE:
battery and battery tray, refer to GROUP 054
AIR-CLEANER INSTALLATION
NOTE:
Air-cleaner, refer to GROUP 015 – Air-cleaner

23 CVT
NOTE

FRONT AXLE 26
Content /1
26 FRONT AXLE
SPECIFICATIONS ....................................................................... 26/2
SERVICE SPECIFICATIONS .......................................................... 26/2
LUBRICANTS ......................................................................... 26/2
SPECIAL TOOLS ........................................................................ 26/2

TOOLS ................................................................................. 26/2
DRIVE SHAFT ........................................................................... 26/3

DISASSEMBLY AND REASSEMBLY <FOR CVT TRANSMISSION> ............ 26/6
DISASSEMBLY AND REASSEMBLY <FOR MANUAL TRANSMISSION> ..... 26/8
DISASSEMBLY SERVICE POINTS ................................................... 26/10
REASSEMBLY SERVICE POINTS .................................................... 26/10

26 FRONT AXLE
/2 SPECIFICATIONS
SERVICE SPECIFICATIONS
Items Standard value Limit
Opening dimension of the When the T.J. boot clamp is 3.2 mm (0.13 in) —
special tool (MB991561) crimped (Big clamp and small
clamp)
1.0~1.5 mm —
Crimped width of the T.J. boot clamp
(0.039~0.059 in)
1.0~1.5 mm —
Crimped width of the dynamic damper clamp
(0.039~0.059 in)
CVT M/T
Drive shaft length (Joint point)
RH 685 mm (26.97 in) ± 2 mm 685 mm (26.97 in) ± 2 mm
(0.079 in) (0.079 in)
LH 369 mm (14.53 in) ± 2 mm 369 mm (14.53 in) ± 2 mm
(0.079 in) (0.079 in)
Bar shaft outer diameter 23.9 mm (0.94 in) 23.9 mm (0.94 in)
Standard
Setting of boot clamp (Big band to
small clamp)
B.J. 89 mm (3.5 in) (RH/LH) 89 mm (3.5 in) (RH/LH)
T.J. 92.25 mm (3.63 in) (RH/LH) 92.25 mm (3.63 in) (RH)
92.65 mm (3.65 in) (LH)
LUBRICANTS
Items Specified lubricant Quantity
Repair kit grease CVT M/T
T.J. boot grease
(ONE LUBER-C) 127 g (4.48 oz, 1.27 N) 111 g (3.92 oz, 1.11 N)
TOOLS
EZT 0041 Oil seal protector
DOIMC026R07013

FRONT AXLE 26
DRIVE SHAFT /3
To crimped the T.J boot

MB991561 Clipping tool and dynamic damper
clamp
DOIIC026R9016
To install the drive shaft

MD998382 Installer
dust shield
DOIMC026R11018
To install the drive shaft

MD998822 Installer adapter
dust shield
DOIMC026R11017
DRIVE SHAFT WCH026SPROC11001
REMOVAL SERVICE POINTS

DRIVE SHAFT RH/LH REMOVAL (FOR CVT)
the drive shaft.
CAUTION
(1) Do not pull on the drive shaft; to prevent
T.J, from damage, please use the pry bar.
cause it will damage the transmission
dust shield and oil seal.
(3) After removing drive shaft, the dust
shield must be replaced.
Please ensure the installation of drive
shaft must use new dust shield.
2. Use the shop towel to cover the transmission
case in order to prevent foreign material get
into the case hole.
DOIMC023R11039

26 FRONT AXLE
/4 DRIVE SHAFT
DRIVE SHAFT RH/LH REMOVAL (FOR

MANUAL TRANSMISSION)
the drive shaft.
CAUTION
(1) Do not pull on the drive shaft; to prevent
T.J, from damage, please use the pry bar.
cause it will damage the transmission
dust shield and oil seal.
(3) After removing drive shaft, the dust
shield must be replaced.
Please ensure the installation of drive
shaft must use new dust shield.
2. Use the shop towel to cover the transmission
case in order to prevent foreign material get
into the case hole.
DOIMC022R11036

DRIVE SHAFT RH/LH INSTALLATION
CAUTION:
(1) Never reuse differential side oil seal.
(2) During installation, never incline differential
side oil seal.
(3) Never damage clutch housing and transmis-
sion case.
(4) Check oil level and oil leakage after installa-
tion.
DOIMC023R11042
For details, please refer GROUP 022 and GROUP
023.
1. Locate the special tool EZT 0042 at the
transmission oil seal area as shown in the il-
lustration.

FRONT AXLE 26
DRIVE SHAFT /5

the transmission oil seal hole.
NOTE:
DOIMC023R11043

26 FRONT AXLE
/6 DRIVE SHAFT
DISASSEMBLY AND REASSEMBLY <FOR CVT TRANSMISSION> WCH026SASSY11001
DOIMC026R11012
Symbol :
— Non-reusable part
Grease : ONE LUBER-C =127 g (4.48 oz, 1.27 N) (T.J. SIDE RH/LH)
CAUTION
(1) Never disassembly the B.J. assembly except when replacing the B.J.
(2) On vehicle with ABS, be sure not to damage the rotor attached to the B.J. outer race.

FRONT AXLE 26
DRIVE SHAFT /7
Disassembly steps
1. Circlip
2. Dust shield
3. Omega big clamp
4. Low profile small clamp
5. T.J. case
6. Snap ring
7. Spider assembly
8. T.J. boot
9. Omega clamp
10. Dynamic damper
11. B.J. assembly

26 FRONT AXLE
/8 DRIVE SHAFT
DISASSEMBLY AND REASSEMBLY <FOR MANUAL TRANSMISSION>
DOIMC026R11013
Symbol :
— Non-reusable part
Grease : ONE LUBER-C = 111 g (3.92 oz, 1.11 N) (T.J. SIDE RH/LH)
CAUTION
(1) Never disassembly the B.J. assembly except when replacing the B.J.
(2) On vehicle with ABS, be sure not to damage the rotor attached to the B.J. outer race.

FRONT AXLE 26
DRIVE SHAFT /9
Disassembly steps
1. Circlip
2. Dust shield
3. Omega big clamp <RH>
4. Low profile small clamp <RH>
5. Low profile big clamp <LH>
6. Omega small clamp <LH>
7. T.J. case
8. Snap ring
9. Spider assembly
10. T.J. boot
11. Omega clamp
12. Dynamic damper
13. B.J. assembly

26 FRONT AXLE
/ 10 DRIVE SHAFT
DISASSEMBLY SERVICE POINTS

WCH026SPROC11002
DUST SHIELD REMOVAL

Use the flat screw driver to remove the dust
shield.
DOIMC026R11001
T.J. BOOT LOW PROFILE CLAMP <BIG OR

SMALL> REMOVAL
Use the long nose plier to remove the low profile
clamp.
DOIMC026R11016
REASSEMBLY SERVICE POINTS

DYNAMIC DAMPER INSTALLATION
1. Install the dynamic damper where feature is
facing T.J. side as shown by the arrow in the
illustration.
DOIMC026R11008

FRONT AXLE 26
DRIVE SHAFT / 11
2. Install the dynamic damper in the position

shown in the illustration (Damper position
from small clamp B.J. to end dynamic
damper).
Standard value:
226 mm (8.9 in)
DOIMC026R11009
3. Use the special tool MB991561 to crimp the

Dynamic damper clamp.
CAUTION
(1) Secure the drive shaft in an upright pos-
ition and clamp the part of the Dynamic
damper to be crimped securely in the
jaws of the special tool.
(2) Crimp the Dynamic damper until the
special tool touches the stopper.
DOIMC026R11002
4. Check that the crimped amount of the Dy-

namic damper clamp is at the standard value.
Standard value:
1.0~1.5 mm (0.039~0.059 in)
DOIMC026R11003
SPIDER ASSEMBLY / SNAP RING

INSTALLATION
1. Apply the specified grease furnished in the
repair kit to the spider assembly between
the spider axle and the roller.
Specified grease:
Repair kit grease (ONE LUBER-C)
CAUTION
(1) The drive shaft joint uses special grease.
Do not mix old and new or different
DOIMC026R11010 types of grease.

26 FRONT AXLE
/ 12 DRIVE SHAFT
(2) If the spider assembly has been cleaned

, take special care to apply the specified
grease
2. Install the new spider assembly to the shaft
from the direction of the spline bevelled
section.
3. Install the snap ring to the drive shaft with
the snap ring pliers.
4. After applying the specified grease to the
T.J. case , insert the drive shaft and apply
grease one more time.
Specified grease (ONE LUBER-C) :
CVT M/T
127 g (4.48 oz, 1.27 111 g (3.92 oz, 1.11
N) N)
NOTE
The grease in the repair kit should be divided
in half for use , respectively at the joint and
inside the boot.
DOIKC026R03005
CAUTION
The drive shaft joint uses special grease. Do
not mix old and new or different types of
grease.
T.J. BOOT INSTALLATION

Set the T.J. boot at the specified distance (as
shown in the illustration) in order to adjust the
amount of air inside the T.J. boot. Then tighten
the T.J. boot clamps securely.
Standard value (A) :
CVT M/T
92.25 mm (3.63 in) 92.25 mm (3.63 in) (RH)
(RH/LH) 92.65 mm (3.65 in) (LH)
DOIMC026R11011
T.J. BOOT OMEGA CLAMP <BIG OR SMALL>

INSTALLATION
1. Use the special tool MB991561 to crimp the
T.J. boot Omega clamp.
CAUTION
(1) Secure the drive shaft in an upright pos-
ition and clamp the part of the T.J. boot
omega clamp to be crimped securely in
the jaws of the special tool.
(2) Crimp the T.J. boot omega clamp until
the special tool touches the stopper.
DOIMC026R11004

FRONT AXLE 26
DRIVE SHAFT / 13
2. Check that the crimped amount of the Dy-

namic damper clamp is at the standard value.
Standard value:
1.0~1.5 mm (0.039~0.059 in)
DOIMC026R11005
T.J. BOOT LOW PROFILE CLAMP <BIG OR

SMALL> INSTALLATION
1. Use the long nose plier to install the low
profile clamp.
DOIMC026R11016
DUST SHIELD <CVT> INSTALLATION

1. Insert the dust shield to the B.J shaft as
DOIMC026R11014
2. Use the special tools MD998382 and

MD998822 to install the dust shield.
CAUTION
Use care during installation so as not to damage
the dust shield.
DOIMC026R11015

26 FRONT AXLE
/ 14 DRIVE SHAFT
DUST SHIELD <M/T> INSTALLATION

1. Insert the dust shield to the B.J shaft as
DOIMC026R11006
2. Use the special tool MD998382 to install the

dust shield.
CAUTION
Use care during installation so as not to damage
the dust shield.
DOIMC026R11007

POWER PLANT MOUNT 32
Content /1
32 POWER PLANT MOUNT

ENGINE MOUNTING ................................................................. 32/2
INSTALLATION SERVICE POINT .................................................. 32/4
TRANSMISSION MOUNTING ........................................................ 32/5

BRACKET ASSY FRONT ROLL MOUNTING ........................................ 32/9


/2 ENGINE MOUNTING
ENGINE MOUNTING WCH032SASSY11001
DOIMC032R11009
Pre-removal operation
• Jack up the engine and transmission assembly until there is no weight on the engine mount
bracket insulator.
Removal steps
1. Power steering pressure hose clamp mounting bolt
2. A/C hose section flexible bracket mounting bolt
3. Engine mounting bolt
4. Engine mounting nut
5. Engine mount insulator mounting bolt
6. Engine mount bracket
7. Engine mount stopper
CAUTION
Mounting locations marked by * should be provisionally tightened, and then fully tightened when
T1 : 0.9~1.4 kgm (9~14 Nm, 6.51~10.13 ft.lbs)
T3* : 10.0 kgm (100 Nm, 72.33 ft.lbs) ± 1.0 kgm (10 Nm, 7.23 ft.lbs)

ENGINE MOUNTING /3
ENGINE MOUNTING BRACKET REMOVAL

1. Use the garage jack to support the engine.
DOIMC032R11011
2. In order to make more easier in removing

engine mounting bracket, remove the air-
cond section flexible bracket mounting bolt.
DOIMC032R11015
3. Remove the power steering pressure hose

clamp mounting bolt.
DOIMC032R11016
4. Remove the engine mounting nuts and bolt.
DOIMC032R11012

/4 ENGINE MOUNTING
5. Remove the engine mount insulator mount-

ing bolt.
DOIMC032R11013
6. Remove the engine mounting bracket assy.
DOIMC032R11014

ENGINE MOUNT STOPPER INSTALLATION
Install the engine mounting stopper so that the
arrow (UP) points in the illustration.
ENGINE MOUNTING BRACKET INSTALLATION

back engine mounting bracket.
DOIMC032R11010

TRANSMISSION MOUNTING /5
TRANSMISSION MOUNTING WCH032SASSY11002
DOIMC032R11001
Non-reusable parts
• Air cleaner assembly removal and installation (Refer to GROUP 015 — Air cleaner).
Removal steps
1. Transmission mount bracket
2. Transmission mount stopper
CAUTION
Mounting locations marked by * should be provisionally tightened, and then fully tightened
when the body is supporting the fully weight of the engine.
T1* : 10.0 kgm (100 Nm, 72.33 ft.lbs) ± 1.0 kgm (10 Nm, 7.23 ft.lbs)

/6 TRANSMISSION MOUNTING
TRANSMISSION MOUNTING BRACKET

REMOVAL
• Support the transmission assy by using garage
jack.
DOIMC032R11002
CVT Transmission:
1. Remove the insulator mounting bolt.
DOIMC032R11003

nuts and bolt.
DOIMC032R11004

assy.
DOIMC032R11005

TRANSMISSION MOUNTING /7
Manual transmission:
1. Remove the insulator mounting bolt.
DOIMC032R11006

nuts.
DOIMC022R11029

assy.
DOIMC032R11007

/8 TRANSMISSION MOUNTING

INSTALLATION
Install the transmission mounting stopper so that
the arrow (UP) points in the direction as shown
TRANSMISSION MOUNTING BRACKET

INSTALLATION
back transmission mounting bracket.
DOIMC032R11008

BRACKET ASSY FRONT ROLL MOUNTING /9
BRACKET ASSY FRONT ROLL MOUNTING WCH032SASSY11003
DOIMC032R11017
Removal steps
1. Bracket assy front roll mounting
2. Bracket assy rear roll mounting
CAUTION
Mounting locations marked by * should be provisionally tightened, and then fully tightened
when the body is supporting the full weight of the engine.
T1* : 5.9~6.4 kgm (59~64 Nm, 42.67~46.29 ft.lbs)

/ 10 BRACKET ASSY FRONT ROLL MOUNTING
NOTE

ANTI-LOCK BRAKE SYSTEM (ABS) 35B
Content /1
35B ANTI-LOCK BRAKE SYSTEM (ABS)

GENERAL INFORMATION ............................................................ 35B/4
OUTLINE OF CHANGES ............................................................. 35B/4
CONSTRUCTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/4
SERVICE SPECIFICATIONS ............................................................ 35B/4

SPECIFICATIONS ..................................................................... 35B/4
SPECIAL TOOLS ........................................................................ 35B/5
TROUBLESHOOTING .................................................................. 35B/6

STANDARD FLOW OF DIAGNOSTIC ............................................. 35B/6
TROUBLESHOOTING GUIDE ....................................................... 35B/7
NOTES WITH REGARD TO DIAGNOSIS .......................................... 35B/7
Noise, Vibration and Harshness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/7
Sponge Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/8
Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/8
DIAGNOSIS FUNCTION ............................................................. 35B/8
DIAGNOSIS CODES CHECK - With the PADT - II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/8
ABS SELF TEST ....................................................................... 35B/8
ABS WARNING LAMP INSPECTION .............................................. 35B/9
ITEMS INDICATED BY THE ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/9
Check that the ABS warning lamp illuminates as follows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/9
PARKING BRAKE WARNING LAMP .............................................. 35B/9
ITEMS INDICATED BY THE PARKING BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 35B/9
PROBLEM DIAGNOSIS CONTENT CHART ....................................... 35B/10
INSPECTION CHART FOR DIAGNOSIS CODE. ................................... 35B/14
INSPECTION PROCEDURE FOR DIAGNOSIS CODES .......................... 35B/15
CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/15
SYSTEM SUPPLY VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/16
CONTROL MODULE PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/18
WHEEL SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/20
BRAKE PEDAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/22
BRAKE PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/24
ABS SYSTEM ACTIVE TOO LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/25
VALVE RELAY SUPPLY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/25
WHEEL SPEED SENSOR GENERIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/27
INSPECTION CHART FOR TROUBLE SYMPTOM ................................ 35B/28
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS ....................... 35B/29
INSPECTION PROCEDURE 1 ........................................................... 35B/29
SERVICE DATA REFERENCE TABLE ................................................. 35B/36

DYNAMIC DATA DISPLAY ......................................................... 35B/36
ACTUATOR TEST REFERENCE TABLE ............................................ 35B/37
ACTUATOR TEST SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/38
CHECK AT ABS-ECU ................................................................. 35B/38
TERMINAL VOLTAGE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/38
RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS . . . 35B/39
INSPECTION PROCEDURE USING AN ANALYZER ................................ 35B/40

WHEEL SPEED SENSOR ............................................................. 35B/40
Analyzer connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/40
Standard Wave Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/41
ALTERNATIVE METHOD- CHECK AT ABS ECU ................................. 35B/42

/2 Content

CAN SIGNAL MEASUREMENT ..................................................... 35B/43
ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU) .............................. 35B/45

REMOVAL AND INSTALLATION ................................................... 35B/45
REMOVAL SERVICE POINT ......................................................... 35B/46
INSTALLATION SERVICE POINT ................................................... 35B/46
INSTALLATION SERVICE POINT ................................................... 35B/46
WHEEL SPEED SENSOR .............................................................. 35B/47

ON-VEHICLE SERVICE ............................................................... 35B/47
REMOVAL SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/47
INSTALLATION SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/48
ON-VEHICLE SERVICE ................................................................. 35B/49

WHEEL SPEED SENSOR CHECK ................................................... 35B/49
BRAKE PEDAL CHECK AND ADJUSTMENT ..................................... 35B/50
STOP LAMP SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/51
BRAKE BOOSTER OPERATING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/51
BRAKE FLUID LEVEL SENSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/52
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/52

Content /3
NOTE

GENERAL INFORMATION WCH35BGINFO10001
OUTLINE OF CHANGES
• Due to the introduction of vehicle variant with ABS system, the service procedure for the brake
booster vacuum hose has been established.
CONSTRUCTION DIAGRAM
DOIMC35BR10001
Symbol Description
1 Hydraulic unit
2 Wheel speed sensor Fr RH / Fr LH
3 ABS rotor Fr RH / Fr LH
4 Stop lamp switch
5 Wheel speed sensor Rr RH / Rr LH
6 ABS rotor Rr RH / Rr LH
7 ABS warning lamp (Integrated in meter combination)
SERVICE SPECIFICATIONS WCH35BSPECS10001
SPECIFICATIONS
Items Standard value / Spec Limit
Wheel speed sensor model Pasline —

SPECIAL TOOLS /5
Items Standard value / Spec Limit

Clearance between speed sensor and ABS
1 mm (0.039 in) ± 0.1 mm (0.004 in)
rotor
-40 °C (-40 °F) – 120 °C (248
Hydraulic unit operating temperature —
°F)
-40 °C (-40 °F) – 115 °C (239
Hydraulic unit storage temperature —
°F)
Hydraulic unit voltage operation 13 V ± 3 V —
Hydraulic unit current operation <30 A —
<120 A (Switch - on current
Hydraulic unit current consumption —
peak)
SPECIAL TOOLS WCH35BSTOOL10001
TOOLS
interface (VCI)
DOIMC35BR11039

CD
DOIMC35BR11042

connector; 1 m) VCI
DOIMC35BR11041

USB cable (1.8 m)
PC and VCI
DOIMC35BR11046

/6 TROUBLESHOOTING

DOIMC35BR11045

Ethernet cable
ing to VCI
DOIMC35BR11040

Cable keeper
cable messy
DOIMC35BR11043

DOIMC35BR11044
DOIMC35BR11047
TROUBLESHOOTING WCH35BSHOOT10001
STANDARD FLOW OF DIAGNOSTIC

Refer to GROUP 000– How to use troubleshooting inspection service points)

TROUBLESHOOTING /7
TROUBLESHOOTING GUIDE
The following steps should be followed during
troubleshooting activity;
1. Observe all symptoms upon receiving com-
plaint from customer. They must be carefully
checked where affected area and part associ-
ated to the problem must be identify.
2. Use PADT-II for proper diagnosis to determ-
ine the root cause of the problem.
3. Always record all trouble code found.
4. Reconfirm failure code by deleting the
trouble code. An intermittent malfunction
will enable the code to be deleted from the
system.
5. Test drive the vehicle more than 40 km/h
(24.85 mph) (refer to Self Test in this
troubleshooting section)
6. Refer to the subsequence pages in this
workshop manual for troubleshooting pro-
cedure (refer to Inspection Chart for Diagnos-
is Code on page 35B/14 )
NOTE
• Do not dismantle the control unit from the
modulator. Warranty will be void.
• Improper diagnose without failure code and
DOIMC35BR11038
failure code clearing process will result in claim
rejection.
NOTES WITH REGARD TO DIAGNOSIS
The phenomenon listed in the following table are not abnormal.
Phenomenon Explanation of phenomenon

System Check sound When starting the engine, a thudding sound can sometimes be heard coming
from inside the engine compartment, but this is because the system operation
check is being performed an is not an abnormal.
ABS operation sound 1. Sound of the motor inside the ABS hydraulic unit operation. (whine)
2. Sound is the generated along with the vibration of the brake pedal.
3. When ABS operates, sound is generated from the vehicle chassis due to
repeated brake application and release. (Thump: suspension; squeak:
tires)
ABS operation (Long For road surfaces such as snow-covered and gravel roads, the braking distance
braking distance) for vehicles with ABS can sometimes be longer than that for other vehicles.
Accordingly, advise the customer to drive safely on such roads by lowering
the vehicle speed and not being too overconfident.
Diagnosis detection condition can vary depending on the diagnosis code. Make sure that checking
requirements listed in the ”Comment” are satisfied when checking the trouble symptom again.
Noise, Vibration and Harshness
ABS systems can make loud noise whilst in operation during heavy braking operation. The level of
noise experienced in one vehicle may be higher than in another, but this does not necessarily indicate
a fault with the noisier vehicle.
Some sources of noise are:

/8 TROUBLESHOOTING
1. ABS Modulator - the modulator contains an electric pump and electrically operated solenoids that
control the brake fluid flow. These items all create noise from the front of the vehicle. If the noise
is of a metallic or grinding nature, check the security of the brake fluid lines and their proximity
to other tubes or vehicle bodywork. Additionally check the ABS Modulator rubber bushings for
correct installation and for contamination with small pebbles or dirt.
2. Tyres - during ABS operation the tyres are at the limits of their adhesion. It is normal for tyre
squeal and slipping noises to be heard.
The ABS systems also means that a certain level of vibration and harshness will be felt during an
ABS stops. The severity is very much dependent on the traction between the road surface and
tyres.
Instances could include:
1. Brake Pedal Pulsation - the brake pedal will pulsate underfoot during an ABS stop. This is due to
the action of the ABS modulator increasing and decreasing brake fluid pressures in various brake
circuits.
2. Vehicle Vibration - an ABS stop involves the violent application of braking forces to individual
wheels to stop a vehicle as quickly as possible whilst maintaining directional control. It should
therefore not be surprising that the vehicle occupants feel a high level of pulsating force as they
are forced forward into their seatbelts. The driver may also perceive that the vehicle is moving
about on the road. However, steering control is maintained to counter any sideway movement
of the vehicle.
Sponge Brake Pedal
This symptom should be treated in exactly the same way as it is for non-ABS vehicles. Check the brake
fluid condition and level and bleed the brake system as per normal.
Brake Bleeding
Bleed the brake system as normal through the calliper bleed screws. Replacement modulators are
filled with brake fluid and should normally only require a conventional bleed procedure to be conduc-
ted. However, if a spongy pedal is present and air in the modulator is suspected, a service bleed should
be carried out.
DIAGNOSIS FUNCTION
DIAGNOSIS CODES CHECK - With the PADT - II
Connect the PADT– II to diagnosis connector
(16–pin), as shown in the illustration.
Symbol Description
A PADT – II vehicle communica-
tion interface ( VCI )
B OBD-II cable
C USB cable
DOIMC35BR11048 CAUTION
Turn the ignition switch off before connecting
or disconnecting the PADT- II.
ERASING DIAGNOSIS CODES
Refer to GROUP-000 – How to use troubleshoot-
ing inspection service points
ABS SELF TEST
When the vehicle is started, the ABS system automatically carries out a static system analysis and wheel
speed sensors are checked for continuity. When the vehicle reaches a speed of 40 km/h, either with
brake applied or not a BITE Test (Build In Test Equipment) is performed. The pump motor and elec-

TROUBLESHOOTING /9
tronic valves are operated and feedback signals from the valves and motor are monitored, to check
correct functionality. The BITE Test maybe heard by the driver.
ABS WARNING LAMP INSPECTION

WCH35BSHOOT10002
Among the self-diagnos items, an ABS warning

lamp turns 'ON' to notifty the driver that the ABS
system is operational or when an irregularity in
ABS system is detected.
Symbol Description
A ABS warning lamp
ITEMS INDICATED BY THE ABS WARNING LAMP
The ABS warning lamp indicates.
DOIMC35BR10002 • ABS system faulty.
• ABS in Special Function / Actuator Function
Check that the ABS warning lamp illuminates as
follows.
1. When the ignition key is turn to “ON”, the
ABS warning lamp illuminates for approxim-
ately 2 seconds and then switches off.
2. When the ignition key is turned to “START”,
the ABS warning lamp remains switched off
3. When the ignition key is turn from “START”
back to “ON” the ABS warning lamp illumin-
ates for approximately 2 seconds and then
stays switches off
4. If the illumination is other than the above,
check the diagnosis codes.
PARKING BRAKE WARNING LAMP
ITEMS INDICATED BY THE PARKING BRAKE
WARNING LAMP
The parking brake warning lamp indicates.
• Parking brake is ON
• Brake fluid is low in brake line .
• Electronic Brake Distribution (EBD) mode
failure.
Symbol Description
B Parking brake warning lamp
DOIMC35BR11006

PROBLEM DIAGNOSIS CONTENT CHART WCH35BSHOOT10003
DIAGNOSIS INDICATOR LAMP

CODE PADT- II DISPLAY PROBABLE CAUSE
CONTENT EBD ABS
1). Short circuit between CAN + and
CAN-
Bus off 2). Short circuit between CAN + and
High Speed CAN UBATT
U0001 Communication 3). Heavy bus disturbance - -
Bus Circuit voltage Supply voltage is below full func-
below threshold tional voltage threshold (9.6 V)
Circuit voltage Supply voltage is above full func-
above threshold tional voltage threshold
ABS/ESP Control General Electric- Watchdog timeout detection. Micro-
U3000 ON ON
Module al Failure controller is faulty.
Circuit voltage Supply voltage is below full func-
ABS/ESP System below threshold tional voltage threshold (9.6 V)
U3003 ON ON
Voltage Circuit voltage Supply voltage is above full func-
above threshold tional voltage threshold
Left Front Inlet
C0010
Control Valve
Left Front Outlet
C0011
Control Valve
Right Front Inlet
C0014
Control Valve
Right Front Outlet
C0015
Control Valve Internal electron- Internal valve related failure has
ON ON
Left Rear Inlet ic failure been detected.
C0018
Control Valve
Left Rear Outlet
C0019
Control Valve
Right Rear Inlet
C001C
Control Valve
Right Rear Outlet
C001D
Control Valve
Circuit short to 1). Motor failure (e.g. blocked)
ground 2). ADC failures.
Circuit short to
Leaking Motor Relay
battery
ABS/ESP Pump Circuit voltage Interruption or under voltage at
C0020 - ON
Motor Control below threshold UBMR
Internal electron-
Failure on the motor relay.
ic failure
RFP mechanical clamp, possibly
Actuator stuck
worn out brushes


CONTENT EBD ABS
1). Short circuit WSS supply line to
UBATT.
2). Short circuit WSS to another
WSS.
General Electric- 3). Short circuit WSS supply line or
al Failure sensor line to GND.
4). Short circuit WSS sensor line to
UBATT.
5). Interruption of WSS supply line
Left Front Wheel or sensor line.
C0031 - ON
Speed Sensor 1). Open circuit in the WSS line
2). Short circuit to UZ in the WSS
line
3). Short circuit to GND in WSS line
Signal plausibil- 4). WSS dislodging from bracket
ity failure 5). Input amplifier in ECU faulty
6). Tooth wheel missing
7). WSS not installed
8). Too great air gap between WSS
and tone wheel
WSS_FL line failure (short circuit
Left Front Wheel supply line or sensor line to GND
Circuit short to
C0032 Speed Sensor Sup- short circuit sensor line to UBATT - ON
battery
ply interruption of supply line or sensor
line).
UBATT.
WSS.
UBATT.
Right Front Wheel or sensor line.
C0034 - ON
line
and tone wheel
WSS_FR line failure (short circuit
Right Front Wheel supply line or sensor line to GND
Circuit short to
battery
line).


CONTENT EBD ABS
UBATT.
WSS.
UBATT.
Left Rear Wheel or sensor line.
C0037 - ON
line
and tone wheel
WSS_RL line failure (short circuit
Left Rear Wheel supply line or sensor line to GND
Circuit short to
battery
line).
UBATT.
WSS.
UBATT.
Right Rear Wheel or sensor line.
C003A - ON
Speed Sensor 1). Open circuit in the WSS line l
line
and tone whee
WSS_RR line failure (short circuit
Right Rear Wheel supply line or sensor line to GND
Circuit short to
C003B Speed Sensor Sup- short circuit sensor line to UBATT - ON
battery
line).


CONTENT EBD ABS
circuit short to
1) Interruption of BLS
battery/ground,
2) Short BLS to Gnd
signal plausibil-
Brake Pedal 3) Short BLS to supply
C0040 ity failure - -
Switch
BLS is set while Accelerate is
signal plausibil-
pressed with no pressure in master
ity failure
cylinder
signal bias level 1) Offset from Pressure sensor is
out of range / >10bar
zero adjustment 2) Pressure sensor sensitivity error
failure >10%
Brake Pressure 1) Interruption of Pressure Signal
C0044 - -
Sensor Line
internal electron- 2) Short Ps Signal to Ground
ic failure 3) Short Ps Signal to Sensorsupply
4) Interruption of Sensorsupply to
Ps
ABS System Active No sub-type in- 1). Incorrect tooth count
C106A ON ON
Too Long formation 2). Permanent bad WSS signal
1). UVR is shorted to ground
Circuit short to
2). Valve driver (Qx) is/are shorted
ground
to ground
1). Defective valve relay (does not
switch OFF)
Circuit short to
2). UVR has a short to UBVR
Valve Relay Supply battery
C100A 3). Status of valve relay gate actu- ON ON
Circuit
ation from system ASIC is wrong.
1). Defective valve relay (does not
switch OFF)
Internal electron-
2). UVR has a short to UBVR
ic failure
3). Status of valve relay gate actu-
ation from system ASIC is wrong.
Internal electron-
C100B Valve Generic General Valve failure has occurred. ON ON
ic failure
Internal electron- Multiple failures or suspected fail-
ic failure ures to the WSS have occurred
Multiple;
1). Open circuit in the WSS line
Wheel Speed 2). Short circuit to UZ in the WSS
C103D ON ON
Sensor Generic Signal compare line
failure 3). Short circuit to GND in WSS line
4). WSS dislodging from bracket
5). Input amplifier in ECU faulty


CONTENT EBD ABS
Not pro-
grammed, Bus
signal/ meassage Wrong ABS variant installed to the
C1000 Variant Code — —
failure. vehicle
Incorrect com-
ponent installed
INSPECTION CHART FOR DIAGNOSIS CODE. WCH35BSHOOT10004
Get an understanding of the problem diagnosis content and check according to the inspection dia-
gnosis chart.
CODE PADT- II DISPLAY REFERENCE PAGE

U0001 High Speed CAN Communication Bus 35B/15
U3003 ABS/ESP System Voltage 35B/16
U3000 ABS/ESP Control Module
C0010 Left Front Inlet Control Valve
C0011 Left Front Outlet Control Valve
C0014 Right Front Inlet Control Valve
C0015 Right Front Outlet Control Valve Replace ABS ECU (refer to 35B/45 )
C0018 Left Rear Inlet Control Valve
C0019 Left Rear Outlet Control Valve
C001C Right Rear Inlet Control Valve
C001D Right Rear Outlet Control Valve
C0020 ABS/ESP Pump Motor Control 35B/18
C0031 Left Front Wheel Speed Sensor
C0032 Left Front Wheel Speed Sensor Supply
C0034 Right Front Wheel Speed Sensor
C0035 Right Front Wheel Speed Sensor Supply
35B/20
C0037 Left Rear Wheel Speed Sensor
C0038 Left Rear Wheel Speed Sensor Supply
C003A Right Rear Wheel Speed Sensor
C003B Right Rear Wheel Speed Sensor Supply
C0040 Brake Pedal Switch 35B/22
C0044 Brake Pressure Sensor 35B/24
C106A ABS System Active Too Long 35B/25
C100A Valve Relay Supply Circuit
35B/25
C100B Valve Generic
C103D Wheel Speed Sensor Generic 35B/27
Check the ABS variant installed correct to
C1000 Variant code
the vehicle specification.

INSPECTION PROCEDURE FOR DIAGNOSIS CODES WCH35BSHOOT10009
CAN COMMUNICATION
PADT Display Probable Causes
Code No.U0001 : Can Communication
• CAN communication problem
Code number are output if the ABS-ECU detects an open-circuit • CAN communication problem with
or short-circuit in the CAN communication wire. EMS system
DOIMC35BR11027

DOIMC35BR11021
SYSTEM SUPPLY VOLTAGE WCH35BSHOOT10011

Code No.C3003 – ABS/ESP System Supply Voltage.
• Blown fuse.
This code is output if the ABS-ECU power supply voltage drops • Battery voltage too low, below
below or rises above the rated values. operating value.
Furthermore, if the voltage return to normal, this code is no • Malfunction of wiring harness or
longer output. connector.
• Malfunction of hydraulic unit.
CAUTION
- Before carrying out the following inspection, check the battery level, and recharge it if necessary.
- Check condition of alternator and charge rate. (Refer to chassis electrical group 54A, battery)

DOIMC35BR11029

DOIMC35BR11023
CONTROL MODULE PUMP MOTOR . WCH35BSHOOT10010

Code No.C0020 – ABS/ESP Pump Motor Control.
• Pump motor power connector
(pin1) open/short circuit
• Pump motor GND connection
The ABS – ECU detects open / short circuit at the control (connector pin13) open / short
module pump motor. circuit.
• Internal electronic failure
• Actuator stuck

DOIMC35BR11028

DOIMC35BR11022
WHEEL SPEED SENSOR WCH35BSHOOT10008

Code No.C0031 , C0032 , C0034 , C0035 , C0037 , C0038 , C003A and C003B .
Code No.C0031 , C0032 , C0034 , C0035 , C0037 , C0038 , C003A • Malfunction of wheel speed
and C003B are output if the ABS-ECU detects an open circuit sensor.
or short-circuit in the (+) wire or (-) wire in any one of the four • Malfunction of wiring harness or
wheel speed sensors. connector
• When there is no input from any one the four wheel speed • Malfunction of ABS rotor.
sensors when travelling at several km/h or more, even • Too much gap between the sensor
though open circuit can not be verified. and the rotor
• Malfunction of hydraulic unit.
• Malfunction of wheel bearing

DOIMC35BR11026

DOIMC35BR11020
BRAKE PEDAL SWITCH WCH35BSHOOT11010

Code No.C0040 – Brake Pedal Switch
• Stop lamp switch failure.
ABS – ECU detects malfunction in stop lamp switch. • Open/Short circuit.
• Faulty input stage in ECU.

DOIMC35CR11022

DOIMC35CR11009
BRAKE PRESSURE SENSOR WCH35BSHOOT11011

Code No.C0044 – Brake Pressure Sensor
• ABS unit has recorded positive hydraulic brake pressure • Signal has level out of range.
with no stop light input. • Zero adjustment failure.
• Stop light input has remained constant for over 1 minute • internal electronic failure.
without positive hydraulic brake pressure.
DOIMC35CR11010

ABS SYSTEM ACTIVE TOO LONG WCH35BSHOOT11008

Code No.C106A – ABS System Active Too Long
• Incorrect tooth count.
The ABS – ECU detects the abnormality in wheel speed sensor. • Permanent bad wheel speed
sensor signal.
NOTE
Code will be displayed in certain driving conditions, for example on a circular test track or when
driving in circle for an extended time period. In most cases the code will roll out on next ignition key
cycle or the code may need to be cleared using the PADT.
DOIMC35CR11014
VALVE RELAY SUPPLY CIRCUIT WCH35BSHOOT11004

Code No.C100A – Valve relay supply circuit
Code No.C100B – Valve generic
• Value relay supply circuit (pin 25)
The ABS – ECU detects open / short circuit at the valve relay open/short circuit.
supply circuit. • Internal electronic failure

DOIMC35BR11025

DOIMC35BR11019
WHEEL SPEED SENSOR GENERIC WCH35BSHOOT11009

Code No.C103D – Wheel Speed Sensor Generic
• Wheel speed sensor swapped.
ABS – ECU detects multiple failures or suspected failures to • Wheel speed sensor setting incor-
the wheel speed sensor have occurred. rect.
• Wheel speed sensor malfunction.

DOIMC35BR11036
INSPECTION CHART FOR TROUBLE SYMPTOM WCH35BSHOOT10012
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Trouble Symptom Inspection procedure No. Reference page

Communica- Communication with all system is not
1 35B/29
tion with possible.
PADT-II is
not pos- Communication with ABS only is not
2 35B/30
sible. possible.
When the ignition key is turned to “ON” (engine
stopped), the ABS warning lamp does not illumin- 3 35B/32
ate.
After the engine starts, the lamp remains illumin-
4 35B/34
ated
CAUTION
1 - ABS may operate in the following conditions even in normal braking condition: Slippery road
surface, high-speed turn, and bumpy road surface. When asking the customers, confirm that they
have/have not encountered ABS operation in corresponding conditions.
2 - During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such
phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent
the wheels from locking and is not an abnormality.

3 - During diagnosis, a diagnosis code associated with other system may be set when the ignition
switch is turned on with connector(s) disconnected. On completion, confirm all systems for dia-
gnosis code(s). If diagnosis code(s) are set, erase them all.
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS WCH35BSHOOT10013
INSPECTION PROCEDURE 1
Communication between the VCI / PADT and the
Probable cause
whole system is not possible
• Malfunction of diagnosis connector.
• Malfunction of wiring harness or connector.
The cause may be a malfunction of the power supply • Conflict in wireless connection in PADT due
circuit or the earth of the diagnosis connector. to high interference
• Battery voltage too low
DOIMC35BR11030

DOIMC35BR11001
INSPECTION PROCEDURE 2 WCH35BSHOOT10014
Communication between VCI / PADT is possible.

Probable cause
(Communication with ABS is not possible)
The cause may be an open circuit in the ABS-CU • Blown fuse
power circuit or an open circuit in the diagnosis out- • Malfunction of wiring harness or connector
put circuit. • Malfunction of ABS-ECU

DOIMC35BR11031

DOIMC35BR11002
When ignition key is turned to “ON” (engine stopped).

Probable cause
ABS warning lamp does not illuminate.
• Blown fuse
• Burnt out ABS warning lamp LED di-
The cause may be an open circuit in the lamp power supply ode.
circuit, a blown lamp LED diode , an open circuit between • Malfunction of wiring harness or
CAN HI and CAN LO Line. connector
• ABS ECU malfunction

DOIMC35BR11032

DOIMC35BR11037
Even after the engine is started, the ABS warning

Probable cause
lamp remains illuminated.
The cause is probably a short – circuit, in the ABS • Malfunction of combination meter
warning lamp illumination circuit. • Malfunction of wiring harness or ( short
circuit)
• Malfunction of hydraulic unit
NOTE
This trouble symptom is limited to cases where communication with the PADT is possible (ABS-CU
power supply is normal) and the diagnosis code is a normal diagnosis code.

DOIMC35BR11033

/ 36 SERVICE DATA REFERENCE TABLE
DOIMC35BR11003
SERVICE DATA REFERENCE TABLE WCH35BSHOOT10007
DYNAMIC DATA DISPLAY

• All loads (lamps, electrical cooling fan and accessories should be OFF all the time during the test.
• Let the engine runs for 10 to 15 mins or until the engine temperature reach 80 degree celcius (engine
runs in hot condition)
• When the vehicle is running, there may be delay in ABS ECU data processing. Therefore the data
value displayed may not in real time.

SERVICE DATA REFERENCE TABLE / 37
NO Dynamic Data Check condition Standard value Remarks

1 Vehicle Speed 0 km/h
Wheel Speed Sensor Front
2 0 km/h
Left
Wheel Speed Sensor Front
3 0 km/h “PADT-II” display is identical
Right
to speedometer indication
Wheel Speed Sensor Rear
4 0 km/h
Left
Wheel Speed Sensor Rear
5 0 km/h
Right
6 Battery Voltage V
System voltage 12~14 V
Brake light switch (BLS) Brake light status “ON”
7 ON/OFF/Faulty
status when brake pedal is pressed.
Vehicle Moving Pump motor status when the
8 Pump Motor Status ON/OFF
pump motor activated.
NOTE “ON” when the Front
9 Front Left Inlet Valve When the vehicle is ON/OFF Rightont Left inlet valve is
stationary wheel opened.
speed reading is 0
km/h “ON” when the Front
10 Front Left Outlet Valve Standard value will ON/OFF Rightont Left outlet valve is
be based on vehicle closed.
speed. “ON” when the Front
11 Front Right Inlet Valve ON/OFF Rightont Right inlet valve is
opened
“ON” when the Front
12 Front Right Outlet Valve ON/OFF Rightont Right outlet valve
is closed
“ON” when the Rear Left in-
13 Rear Left Inlet Valve ON/OFF
let valve is opened
“ON” when the Rear Left
14 Rear Left Outlet Valve ON/OFF
outlet valve is closed
“ON” when the Rear Right
15 Rear Right Inlet Valve ON/OFF
inlet valve is opened
“ON” when the Rear Right
16 Rear Right Outlet Valve ON/OFF
outlet valve is closed
Note:
Inlet valve (normally open valve) is activated when the valve is closed.
Outlet valve (normally closed valve) is activated when the valve is opened.
ACTUATOR TEST REFERENCE TABLE WCH35BSHOOT10006
The PADT activates the following actuator for testing.

NOTE
1 - Actuator testing is only possible when the vehicle is stationary. If the vehicle speed during actuator
testing exceeds 10 km/h, force actuator will be canceled.
2 - The ABS warning lamp will be ON while actuator test is carried out

/ 38 SERVICE DATA REFERENCE TABLE
ACTUATOR TEST SPECIFICATION

No. Item Remark
Clicking sound can be heard
Pump motor in the hydraulic
1 Pump motor at the valve indicating pump
unit .
motor operation.
2 Inlet Valve FL
3 Outlet Valve FL
4 Inlet Valve FR
5 Outlet Valve FR Solenoid valve and pump Clicking sound can be heard
motors in the hydraulic unit at the valve indicating the
6 Inlet Valve RL . valve is opened / closed.
7 Outlet Valve RL
8 Inlet Valve RR
9 Outlet Valve RR
CHECK AT ABS-ECU WCH35BSHOOT11005
Remove the harness connector cover and meas-

ure the terminal voltage of the ABS-ECU at har-
ness side.
1. Measure the voltages between each respect-
ive terminal.
The terminal layouts are shown in the illustra-
tions below.
DOIMC35BR10003
Connector termin- Checking require-

Check item Normal condition
al No. ments
Motor relay and ABS
ECU
Valve relay power and
ECU relay
Ignition switch : ON System voltage
28 ABS ECU relay Ignition switch :
0V
START
Brake light ON > 9.5 V
30 Brake light input
Brake light OFF <2V

SERVICE DATA REFERENCE TABLE / 39
RESISTANCE AND CONTINUITY BETWEEN

HARNESS-SIDE CONNECTOR TERMINALS
1. Turn the ignition switch off and disconnect
the ABS-ECU connectors before checking
resistance and continuity.
2. Check them between the terminals indicated
in the table below
3. The terminal layouts are shown in the illus-
tration below.
DOIMC35BR10003
Connector terminal No. Signal Normal condition

8 and 19 Front-left wheel speed sensor
31 and 18 Rear left wheel speed sensor
Continuity
17 and 29 Rear right wheel speed sensor
4 and 16 Front-right wheel speed sensor
14 and 26 CAN 1 Refer to 35B/43
13 and ground Ground monitoring motor and motor relay
Continuity
38 and ground ABS ECU ground

/ 40 INSPECTION PROCEDURE USING AN ANALYZER
INSPECTION PROCEDURE USING AN ANALYZER WCH35BSHOOT11002
WHEEL SPEED SENSOR

Analyzer connection
DOIMC35BR11035
CONNECTION FOR WHEEL SPEED SENSOR

Description
A) (+) terminal of the analyzer to • pin terminal no. 1 wheel speed sensor
B) (-) terminal of the analyzer to • pin terminal no. 2 wheel speed sensor and ground
1. Disconnect the wheel speed sensor connector and connect the special tool (test harness MB 991348)
in between. All terminals should be connected.
2. Connect the analyzer to the test harness to pickup the wheel speed sensor signal at pin no. 1 and
pin no. 2 of the wheel speed sensor to ground.
3. Turn the ignition switch ON.
4. Turn the wheel by hand at approximately 1 revolution per second or drive on brake dynometer
at 5 km/h (3.11 mph).
NOTE
Recommended analyzer setting;
• Y-axis: 2V
• X-axis: 100ms
Repeat the procedure for all the wheel speed sensor

INSPECTION PROCEDURE USING AN ANALYZER / 41
Standard Wave Pattern
DOIMC35BR11016
Symbol Description
Output voltage;
V High (range from 0.9 V to 1.5 V)
Low (range from 0.3 V to 0.8 V)
T Time varies according to wheel speed
1. Check the wave generated by the analyzer is the same as the standard wave form when the wheels
is turn at a constant speed.
2. Check that the time (cycle time) ,t is reduced when the wheel speed increases.
3. If the wave generated is different from the standard waveform, replace the wheel speed sensor.

ALTERNATIVE METHOD- CHECK AT ABS ECU

Analyzer connection
DOIMC35BR11013
CONNECTION FOR FRONT LH WHEEL SPEED SENSOR

Description
A) (+) terminal of the analyzer to • pin terminal no. 19 ABS ECU
B) (-) terminal of the analyzer to • pin terminal no.8 ABS ECU
1. Disconnect the ABS ECU connector and connect the special tool (test harness MB 991348) in
between. All terminals should be connected.
2. Connect the analyzer to the test harness to pickup the wheel speed sensor signal.
4. Turn the front LH wheel by hand at approximately 1 revolution per second or drive on brake
dynometer at 5 km/h (3.11 mph).
NOTE
• Y-axis: 2V
• X-axis: 100ms
Repeat the procedure for all the wheel speed sensor;

INSPECTION PROCEDURE USING AN ANALYZER / 43
CONNECTION Description
A) (+) terminal of the ana-
• pin terminal no.16 (A-41) ECU
Front RH Wheel speed lyzer to
sensor B) (-) terminal of the ana-
lyzer to
Rear RH Wheel speed lyzer to
lyzer to
Rear LH Wheel speed lyzer to
lyzer to
DOIMC35BR11016
Symbol Description
Output voltage; contant (range from 0.5 V to
V
2.0 V)
T Time varies according to wheel speed
1. Check the wave generated by the analyzer is the same as the standard wave form when the wheels
is turn at a constant speed.
2. Check that the time (cycle time),t is reduced when the wheel speed increases.
3. If the wave generated is different from the standard waveform, replace the wheel speed sensor.
CAN SIGNAL MEASUREMENT WCH35BSHOOT11003
Analyzer connection
DOIMC35BR11017

CONNECTION DESCRIPTION
Channel 1: Pin terminal no. 6 Diagnosis connector to pin terminal no. 5 Diagnosis CAN-HI
connector
Channel 2: Pin terminal no. 14 Diagnosis connector to pin terminal no. 4 Diagnosis CAN-LO
connector
1. Connect the analyzer to the test harness to pickup the CAN signal.
3. Observe the voltage signal using the analyzer.
NOTE
• Y-axis: 5V
• X-axis: 100ms
DOIMC35BR11018
1. Check the wave generated by the analyzer is the same as the standard wave form.
2. Check that the voltage value;
SYMBOL STANDARD VALUE DESCRIPTION

V1 - 0.12- - - - V ~ 0.12 V DIFFERENTIAL RECESSIVE VOLTAGE
V2 1.2 V ~ 3.0 V DIFFERENTIAL DOMINANT VOLTAGE
3. If the wave generated and the voltage value is different from the standard, check the wiring
harness.

ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU) / 45
ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU) WCH35BSASSY10001
DOIMC35BR10009
• Brake fluid draining.
• Brake line bleeding.
• Brake pedal adjustment.
Removal steps
1. ABS-ECU connector 7. Brake pipe connection MC2
2. 8. Bracket assy
Brake pipe connection RL
3. 9. Electronic Hydraulic Control Unit (EHCU)
Brake pipe connection FR
4. 10. Nut 10m
Brake pipe connection FL
5. 11. Washer
Brake pipe connection RR
6. 12. Damper rubber
Brake pipe connection MC1
T1:1.3-1.7 kgm (13-17 Nm, 9.4-12.3 ft.lbs)
T2:0.9-1.4 kgm (9-14 Nm, 6.51-10.13 ft.lbs)
A : Tube assy

/ 46 ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU)
REMOVAL SERVICE POINT WCH35BSPROC10004
HYDRAULIC UNIT ASSEMBLY REMOVAL

CAUTION
(1) The hydraulic unit assembly is heavy and be
carefully during removal.
(2) The hydraulic unit assembly cannot be disas-
sembled.
(3) The hydraulic unit assembly must not be
dropped or otherwise subjected to impact
shocks.
(4) The hydraulic unit assembly must not be
turned upside down or laid on its side.
BRAKE PIPE CONNECTION
Connect the pipes to the hydraulic unit assembly
Symbol Description
1 To w/cylinder (FR)
2 To w/cylinder (RL)
3 To w/cylinder (RR)
4 From the master cylinder (Secondary)
DOINC35BR10001
5 From the master cylinder (Primary)
A Hydraulic unit ( EHCU)
HYDRAULIC UNIT ASSEMBLY REMOVAL

CAUTION
(1) The hydraulic unit assembly is heavy and be carefully during removal.
(2) The hydraulic unit assembly cannot be disassembled.
(3) The hydraulic unit assembly must not be dropped or otherwise subjected to impact shocks.
(4) The hydraulic unit assembly must not be turned upside down or laid on its side.
ABS CONNECTOR
Connector ABS to the hydraulic unit assembly as
Symbol Description
A Push Lock connector
B Pull – up lever
DOIMC35BR11008

WHEEL SPEED SENSOR / 47
DOIMC35BR11009
WHEEL SPEED SENSOR WCH35BSPROC10003
ON-VEHICLE SERVICE
FRONT SPEED SENSOR / REAR SPEED SENSOR

REMOVAL
CAUTION
Be careful when handling the pole piece (PP) at
the tip of the speed sensor and the rotor teeth.
Do not damage the components by striking it
against the metal parts.
Symbol Description
A Front axle portion
B Rear axle portion
C Front speed sensor
D Rear speed sensor
PP Pole piece
T1: 0.5 ± 0.1 kgm (5 ± 1 Nm, 3.62 ± 0.72 ft.lbs)
DOIMC35BR10006

/ 48 WHEEL SPEED SENSOR
FRONT SPEED SENSOR / REAR SPEED

SENSOR INSTALLATION
FRONT SPEED SENSOR INSTALLATION
CAUTION
Be careful the pole piece (PP) at the end of the
speed sensor and the toothed edge of the rotor.
Ensure that the wheel speed sensor is free from
any particle, dirt or dust. Gently wipe the tip of
the sensor with a clean cloth.
Insert a thickness gauge into the space between
the speed sensor's pole piece and the rotor's
toothed surface. Then, tighten the speed sensor
bracket at the position where the clearance is
the standard value all around.
Standard value (C):
1.0 ± 0.1 mm (0.039 ± 0.004 in)
Symbol Description
A Front sensor
B Front rotor
DOIMC35BR10004 C 1.0 ± 0.1 mm (0.039 ± 0.004 in)
E ABS front sensor

REAR SPEED SENSOR INSTALLATION

CAUTION
Be careful the pole piece (PP) at the end of the
speed sensor and the toothed edge of the rotor.
Ensure that the wheel speed sensor is free from
any particle, dirt or dust. Gently wipe the tip of
the sensor with a clean cloth.
Insert a thickness gauge into the space between
the speed sensor's pole piece and the rotor's
toothed surface. Then, tighten the speed sensor
bracket at the position where the clearance is
the standard value all around.
Standard value (C):
1.0 ± 0.1 mm (0.039 ± 0.004 in)
Symbol Description
A Rear sensor
B Rear rotor
C 1.0 ± 0.1 mm (0.039 ± 0.004 in)
F ABS rear sensor
DOIMC35BR10005
ON-VEHICLE SERVICE WCH35BSPROC11001
WHEEL SPEED SENSOR CHECK

CAUTION
Be careful not to touch the connector (resin
section) with the tool when removing and in-
stalling. Make sure the engine stops from run-
ning when replacing or connecting the compon-
ent.
Symbol Description
A Wheel speed sensor
DOIMC35BR11014
B Wheel speed sensor harness con-
nector (A-40, A-39 ,E-21, E-20)
C ABS ECU
D ABS ECU harness connector (A-41)

1. Remove the wheel speed sensor.

2. Disconnect the ABS ECU connector.
3. Check at the harness side;
Connect- Pin terminal Description

or
A-41 8 and 19 Wheel speed
sensor Front LH
Condition: Ignition switch ON
1. Continuity check, OK: continuity
2. Short circuit (to ground/battery), OK: no
short circuit
DOIMC35BR11015 NO GOOD: Check the wiring harness. If
problem still exist, replace wheel speed
sensor. If all test fail, replace ABS ECU.
4. Repeat test for other wheel speed sensor
Pin terminal Description

Wheel speed sensor
4 and 16
Front RH
Wheel speed sensor Rear
17 and 29
RH
Wheel speed sensor Rear
31 and 18
LH
BRAKE PEDAL CHECK AND ADJUSTMENT

WCH35BSPROC10001
1. Measure the brake pedal height as illus-

trated. If the brake pedal height is not within
the standard value, adjust or replace.
Symbol Description
A Operating rod
B Operating rod lock nut
C Stop lamp switch
D Brake pedal height
DOIIC35AR9005 Standard value:
163.4- 166.4 mm (6.43- 6.55 in) (D).
1.1 Disconnect the stop lamp switch con-

nector.
1.2 Adjust the brake pedal height by turn-
ing the operating rod with pliers (with
the operating rod lock nut loosened),
until the correct brake pedal height is
obtained.
Symbol Description
A Pedal down
B Pedal up
C Lock nut
DOIIC35AR9006

1.3 Secure by tightening the lock nut of the

operating rod.
1.4 Push the stop lamp switch in the direc-
tion of the pedal stroke until it stops. (
The switch will slide if it is pushed
firmly.)
1.5 Connect the connector of the stop lamp
switch.
1.6 Check that the connector of the stop
lamp switch is not illuminated with the
brake pedal unpressed.
2. Start the engine, depress the brake pedal
with the approximately 49.0 kg (490 N,
108.04 lbs) of force, and measure the clear-
ance between the brake pedal and the floor
board.
Standard :
80 mm (3.15 in) or more
If the clearance is outside the standard value,

check for air trapped in the brake line,
clearance between the lining and the drum
and dragging in the parking brake . Adjust
DOIIC35AR9009 and replace defective parts as required.
STOP LAMP SWITCH CHECK
Connect a circuit tester to the stop lamp switch,
and check whether or not there is continuity
when the plunger of the stop lamp switch is
pushed in the and when it is released. The stop
lamp switch is in good condition if there is no
continuity when the plunger is pushed in to a
depth of within 4 mm (0.16 in) from the outer
case edge surface, and if there is continuity when
it is released
Symbol Description
DOIIC35AR9010
A 4 mm (0.16 in)
B No continuity
C Continuity
BRAKE BOOSTER OPERATING TEST
For simple checking of the brake booster opera-
tion, carry out the following tests:
1. Run the engine for one or two minutes, and
then stop it
If the pedal depress fully the first time but
gradually becomes higher when depressed
succeeding times, the booster is operating
properly, if the pedal height remains un-
changed, check the vacuum supply.
Symbol Description
DOIIC35AR9011
A Good

Symbol Description
B No good
2. With the engine stopped, step on the brake
pedal several times.
Then step on the brake pedal and start the
engine
If the pedal moves downward slightly, the
booster is in good condition. If there is no
change, check the vacuum supply.
Symbol Description
A When engine is stopped
B When engine is started
3. With the engine running, step on the brake
DOIIC35AR9012
pedal and then stop the engine.
Hold the pedal depressed for 30 seconds, If
the pedal height does not change, the
booster is in good condition, if the pedal
rises, check the hydraulic circuit.
If the above tests are okay, the booster per-
formance can be determined as good. If one
of the above three test is not okay at last ,
the check valve , vacuum hose or booster will
be defective.
BRAKE FLUID LEVEL SENSOR CHECK

The brake fluid sensor is in good condition if
there is no continuity when the float surface is
above “MIN” and if there is continuity when the
float surface is below “MIN”.
Symbol Description
A “MIN”
DOIIC35AR9016
BLEEDING
CAUTION
Use the specified brake fluid. Avoid using a
mixture of the specified brake fluid and other
fluid.
• Safety item
• Goggle
• Pour water, to neutral area
Specified brake fluid
: DOT3 or DOT4
DOIIC35AR9017
MASTER CYLINDER BLEEDING
The master cylinder used has no check valve, so
if bleeding is carried out by the following proced-

ure, bleeding of air from the brake pipeline will

become easier. (When brake fluid is not con-
tained in the master cylinder.)
1. Fill the reservoir tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylin-
der outlet with a finger.
4. With the outlet still closed, release the brake
pedal.
5. Repeat steps 2–4. three or four times to fill
the inside of the master cylinder with brake
fluid.
BRAKE PIPE LINE BLEEDING
Bleed the air in the sequence shown in the fig-
ure.
CAUTION
For vehicles with ABS, be sure to install a filter
to the master cylinder reservoir tank when sup-
plying brake fluid.
DOIIC35AR9018

NOTE

SUPPLEMENT RESTRAINT SYSTEM 52B
Content /1
52B SUPPLEMENT RESTRAINT SYSTEM

GENERAL INFORMATION ............................................................ 52B/4
SRS SERVICE PRECAUTIONS ......................................................... 52B/5
SPECIAL TOOLS ........................................................................ 52B/8
TEST EQUIPMENT ..................................................................... 52B/8
PROTON ADVANCE DIAGNOSTIC TOOL (PADT-II) .............................. 52B/9

SPECIAL FUNCTIONS ................................................................ 52B/9
SRS INSPECTION USING SPECIAL FUNCTION IN PADT-II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/9
TROUBLESHOOTING .................................................................. 52B/10

STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING ................... 52B/10
DIAGNOSIS FUNCTION ............................................................. 52B/10
Diagnosis Codes Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/10
Erasing Diagnosis Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/10
SRS WARNING LAMP INSPECTION ............................................... 52B/10
DYNAMIC DISPLAY REFERENCE TABLE ......................................... 52B/10
FAULT CODE REFERENCE TABLE ................................................. 52B/11
FRONT AIRBAG (DRIVER'S SIDE) ................................................. 52B/13
INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/13
POST-INSTALLATION ................................................................ 52B/28
FRONT DRIVER AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/28
INSPECTION .......................................................................... 52B/28
DRIVER FRONT AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/28
FRONT AIRBAG (PASSENGER SIDE) .............................................. 52B/30
PROBABLE CAUSES OF FAULT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/30
INSPECTION PROCEDURE .......................................................... 52B/31
MODULE FAULT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/31
CONTINUITY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/31
PASSENGER FRONT AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/43
INSPECTION .......................................................................... 52B/44
PASSENGER FRONT AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/44
PRE TENSIONER (DRIVER'S SIDE) ................................................. 52B/45
INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/45
DRIVER PRE TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/51
INSPECTION .......................................................................... 52B/52
DRIVER SIDE AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/52
PRE TENSIONER (PASSENGER SIDE) .............................................. 52B/53
PROBABLE CAUSES OF FAULT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/53
PASSENGER PRETENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/60
INSPECTION .......................................................................... 52B/60
PASSENGER PRE TENSIONER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/60

/2 Content
POWER AND METER COMBINATION ............................................ 52B/61

FAULT CODE INSPECTION ......................................................... 52B/61
SRS MAINTENANCE ................................................................... 52B/68

SRS WARNING LAMP CHECK ..................................................... 52B/68
SRS COMPONENT VISUAL CHECK ................................................ 52B/68
SRS Control Unit (SRS-ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/69
Air Bag Modules, Steering Wheel and Clock Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/69
INSTRUMENT PANEL WIRING HARNESS/FLOOR WIRING HARNESS ....... 52B/71
POST INSTALLATION INSPECTION ................................................ 52B/71
POST COLLISION DIAGNOSIS ....................................................... 52B/72

SRS – ECU MEMORY CHECK ...................................................... 52B/72
REPAIR PROCEDURE ................................................................ 52B/72
When Air bag Deploy or Seat Belt Pre-Tensioner Operates in a Collision . . . . . . . . . . . . . 52B/72
When Seat Belt Pre-Tensioner Operates in a Collision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/72
When Air Bag or Seat Belt Pre-Tensioner Does Not Deploy in Low Speed Collision . . . 52B/72
INDIVIDUAL COMPONENT SERVICE ............................................... 52B/73
WARNING / CAUTION LABEL ....................................................... 52B/74
SRS AIR BAG CONTROL UNIT (SRS-ECU) .......................................... 52B/77

REMOVAL AND INSTALLATION ................................................... 52B/77
INSPECTION .......................................................................... 52B/79
INSTALLATION SERVICE POINTS .................................................. 52B/80
POST INSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/81
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/81
AIR BAG MODULE AND CLOCK SPRING .......................................... 52B/82

REMOVAL AND INSTALLATION .................................................. 52B/82
INSPECTION .......................................................................... 52B/85
CLOCK SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/85
INSTALLATION SERVICE POINT .................................................. 52B/85
INSPECTION .......................................................................... 52B/85
AIR BAG MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/85
CLOCK SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/86
CLOCK SPRING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/86
INSPECTION ......................................................................... 52B/89
DRIVER AIR BAG MODULE / FRONT PASSENGER AIR BAG MODULEif so equipped 52B/89
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT PASSENGER AIR BAG MODULE ........................................... 52B/90

INSPECTION ......................................................................... 52B/93
FRONT PASSENGER'S AIR BAG MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/93
AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCED- 52B/94
U R E ......................................................................................
GENERAL INFORMATION .......................................................... 52B/94

Content /3
SEAT BELT WITH PRETENSIONER ................................................... 52B/95

REMOVAL AND INSTALLATION .................................................. 52B/95
PRE-INSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/97
INSPECTION .......................................................................... 52B/97
SEAT BELT WITH PRE-TENSIONER CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/97
UN-DEPLOYED AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOS- 52B/97
A L ........................................................................................
DEPLOYMENT INSIDE THE VEHICLE ............................................. 52B/97
Driver's air bag module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/98
Seat belt pre-tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/100
DEPLOYMENT OUTSIDE THE VEHICLE .......................................... 52B/101
Driver's side air bag module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/102
Seat belt pre-tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/103
DEPLOYED AIR BAG MODULE OR OPERATED SEAT BELT PRE-TENSIONER 52B/105

DISPOSAL PROCEDURES .............................................................

GENERAL INFORMATION WCH52BGINFO11001
CAUTION
• Carefully read and observe the information in SERVICE PRE CAUTIONS (refer page 52B/5 ) prior
to any service.
• For information concerning troubleshooting or maintenance, always observe the procedures in
the TROUBLESHOOTING (refer page 52B/10 ) section.
• If any SRS components are removed or replaced in connection with any service procedures, be
sure to follow the procedures in the INDIVIDUAL COMPONENT SERVICE section (refer page 52B/73
) for the components involved.
• If you have any questions about the SRS, please contact your local distributor.
To improve safety, the SRS and seat belts with pretensioner are available. These systems enhance
collision safety by restraining the front passengers in case of an accident. The frontal airbags (Driver
and Passenger*) work with the pre-tensioner seat belts when a frontal collision is detected at a certain
value.
The SRS consists of two airbag modules, SRS air bag control unit, SRS airbag warning lamp, clock spring
and pre-tensioners. The airbags are located in the center of the steering wheel and above the glove
box. Each airbag has a folded bag and an inflator unit. The airbag control unit situated under the
floor console monitors the system and has a safing impact sensor. The warning lamp on the instrument
panel indicates the operational status of the SRS. The clock spring is installed in the steering column
switch.
The seat belt pretensioner is built into the front seat belt retractor and only works during frontal
collision. Only authorized service personnel should work on or around the SRS components and seat
belt with pre-tensioners. Those service personnel should read this manual carefully before starting
any such work. Extreme care must be given when servicing the SRS to avoid injury to the service per-
sonnel (by inadvertent deployment of the airbags or inadvertent operation of the seat belt with
pretensioner) or the driver (by rendering the SRS or the seat belt with pretensioner inoperative).* If
fitted

SRS SERVICE PRECAUTIONS /5
DOIMC006R10001
Symbol Description
A Clock spring
B Front driver's airbag module
C Airbag Control Unit (SRS ECU)
D Front driver's airbag
E Front passenger's airbag
F Seat belt with pre-tensioner
G Front passenger airbag module
SRS SERVICE PRECAUTIONS WCH52BGINFO11002
1. In order to avoid injury to yourself or others from accidental deployment of the airbag and acci-
dental operation of the seat belt with pre-tensioner during servicing, read and carefully follow
all the pre-cautions and procedures described in this manual.
2. Do not use any electrical test equipment on or near SRS components, execpt those specified on
page ( Refer page 52B/8 — TEST EQUIPMENT)
3. Never Attempt to Repair the following components:
• SRS airbag control unit (SRS-ECU).
• Clock spring.
• Front airbag module (Driver's side or front passenger's side if equipped).
• Side airbag module (if so equipped).
• Side impact sensor (if so equipped).

/6 SRS SERVICE PRECAUTIONS
• Seat belt with pre-tensioner,

NOTE
If any of these components are diagnosed as faulty, they should only be replaced in accordance
with the INDIVIDUAL COMPONENTS SERVICE procedures in this manual, starting at page
(52B/73 )
DOIMC015R07017
4. After the ignition switch has been placed at the LOCK position and the negative (-) terminal of
the battery has been disconnected, wait for at least 5 min. before starting work. Wind a tape
around the disconnected (-) terminal for insulation.
Symbol Description
A Battery cable
B Insulating tape
C Battery
5. Do not attempt to repair the wiring harness connectors of the SRS. If any of the connectors are
diagnosed as faulty, replace the wiring harness. If the wires are diagnosed as faulty, replace or
repair the wiring harness according to the following table
DOIMS000R10001
SRS-ECU Pin
Destination of Harness Corrective Action
No.
1,2 Instrument panel (RH) wiring harness ⇒ Correct or replace the instrument panel
clock spring harness. Replace the clock spring.

SRS SERVICE PRECAUTIONS /7
SRS-ECU Pin
Destination of Harness Corrective Action
No.
5 SRS-ECU pin no 5 ⇒ SRS-ECU pin no 6
8,9 SRS-ECU ⇒ Pre-tensioner (driver's side)
7,30 SRS-ECU ⇒ Pre-tensioner (passenger side)
10 Instrument panel (RH) wiring harness ⇒
meter combination (SRS warning lamp)
11 SRS-ECU ⇒ earth Correct or replace each wiring harness
PCB box fuse no. 12 (10A)
diagnosis connector
DOIMS000R10002
6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure.
• Insert the special tool (as shown in the illustration) into connector from harness side (rear side),
• Connect the tester to this probe. If any to other than the special tool is used, it may cause damage
to the harness and other components. Furthermore, measurement should not be carried out by
touching the probe directly against the terminals from the front of the connector. The terminals
are plated to increase their conductivity, so that if they are touched directly by the probe, the
plating may break, which will cause drops in reliability
7. SRS components and seat belt, with pre-tensioner should not be subjected to heat, so remove the
SRS-ECU, airbag module (driver's side and front passenger's side if equipped), clock spring, side
impact (if equipped), front seat assemblies (side airbag moduleif equipped), and seat belts with
pre-tensioner before drying or baking the vehicle after painting.
• SRS-ECU, airbag module, clock spring, side impact (if equipped) : 93°C or more
• Seat belt with pre-tensioner: 90°C or more
8. Whenever you finish servicing the SRS, check warning lamp operation to make sure the system
functions properly (Refer to page 52B/10 ).
9. Ensure the Ignition Switch is OFF when PADT-II is connected or disconnected.
10. If you have any question about SRS, please contact your local distributor
NOTE
SERIOUS INJURY CAN RESULT FROM UNINTENDED AIRBAG DEPLOYMENT, SO USE ONLY THE
PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.

/8 SPECIAL TOOLS
SPECIAL TOOLS WCH52BSTOOL11001
Tool Part Number Name Use

570465600 Air bag simulat- • To simulate the air
(6pcs) and or and sub har- bag module func-
570763200 ness tion during
(3 pcs) troubleshooting
for safety purpose
DOIKC52BR03134
MB990803 Steering wheel • To remove steer-

puller ing wheel
DOIIC52BR9003
TEST EQUIPMENT WCH52BEQUIP11001
interface (VCI)
DOIMC35BR11039

CD
DOIMC35BR11042

connector; 1 m) VCI
DOIMC35BR11041

USB cable (1.8 m)
PC and VCI
DOIMC35BR11046

PROTON ADVANCE DIAGNOSTIC TOOL (PADT-II) /9

DOIMC35BR11045

Ethernet cable
ing to VCI
DOIMC35BR11040

Cable keeper
cable messy
DOIMC35BR11043

DOIMC35BR11044
DOIMC35BR11047
PROTON ADVANCE DIAGNOSTIC

TOOL (PADT-II) WCH52BSPROC11001
SPECIAL FUNCTIONS
SRS INSPECTION USING SPECIAL FUNCTION IN
PADT-II
• Connect PADT-II to diagnostic connector
(The position of the diagnostic connector
varies between models).
• Switch the ignition key to “ON” position.
• Select the vehicle model to be diagnosed in
DOIMC52BR11004 PADT-II menu.
• Select “ACU-AP2”.

• Click on the ECU ID icon (A) to confirm the

on SRS part number.
• The “Data List” button will display the SRS
components' dynamic values.
DOIMC52BR11003
TROUBLESHOOTING WCH52BTSHOT11001
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

Refer to GROUP 002 – HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
DIAGNOSIS FUNCTION
Diagnosis Codes Check
Connect the PADT to the diagnosis connector (16–pins) under the instrument under cover, then check
diagnosis codes (Refer to GROUP 002, Pub no. RDCE-0800BT010 —HOW TO USE TROUBLESHOOTING/IN-
SPECTION SERVICE POINTS).
Erasing Diagnosis Code
Connect the PADT to the diagnosis connector and erase the diagnosis code.
CAUTION
Turn off the ignition switch before connecting or disconnecting the PADT.
SRS WARNING LAMP INSPECTION
DOIMC52BR10020
1. Check to be sure that the SRS warning lamp illuminates when ignition switch is in ON position.
2. Check to be sure that it illuminates for approximately 7 seconds and then switches off.
3. If the above is not the cause, inspect the diagnosis code.
DYNAMIC DISPLAY REFERENCE TABLE
Dynamic Display Units REMARKS
BATTERY VOLTAGE V 12 V

Dynamic Display Units REMARKS

CAPACITOR VOLTAGE V 12 V
DRIVER FRONT AIRBAG IMPEDANCE 2.1 - 5.5 Ω Firing is ensured.
(1)
PASSENGER FRONT AIRBAG IMPEDANCE 1.6 - 4.0 Ω Firing is ensured.
DRIVER PRETENSIONER IMPEDANCE 1.6 - 4.0 Ω Firing is ensured.
1
PASS PRETENSIONER IMPEDANCE 1.6 - 4.0 Ω Firing is ensured.
1
RIGHT SIDE AIRBAG IMPEDANCE 1.6 - 4.0 Ω Firing is ensured.
1
LEFT SIDE AIRBAG IMPEDANCE 1.6 - 4.0 Ω Firing is ensured.
NOTE:
(1) if vehicle equipped with the system
FAULT CODE REFERENCE TABLE

Fault Code Code name Diagnosed Item Reference Page
B1021 DRIVER FRONT AIRBAG
SHORT CIRCUIT TO GROUND
B1022 DRIVER FRONT AIRBAG
SHORT CIRCUIT TO BATTERY Front air bag driver's
page 52B/13
B1023 DRIVER FRONT AIRBAG side
SHORT CIRCUIT
B1024 DRIVER FRONT AIRBAG OPEN
CIRCUIT
B1026 PASSENGER FRONT AIRBAG
SHORT CIRCUIT TO BATTERY Front air bag passen-
page52B/30
B1028 PASSENGER FRONT AIRBAG ger side
SHORT CIRCUIT
OPEN CIRCUIT
B1031 DRIVER PRETENSIONER
SHORT CIRCUIT TO BATTERY
Driver pretensioner page 52B/45
SHORT CIRCUIT
B1034 DRIVER PRETENSIONER OPEN
CIRCUIT
B1036 PASSENGER PRETENSIONER
SHORT CIRCUIT TO BATTERY Passenger preten-
page52B/53
B1038 PASSENGER PRETENSIONER sioner
SHORT CIRCUIT
OPEN CIRCUIT

Fault Code Code name Diagnosed Item Reference Page

B1011 BATTERY LOW VOLTAGE
B1012 BATTERY HIGH VOLTAGE
B1091 WARNING LAMP SHORT TO Power and meter
page52B/61
GROUND combination line
B1092 WARNING LAMP SHORT TO
BATTERY
B1002 DRIVER FRONTAL AIRBAG Do not attempt to troubleshoot
DEPLOYED error. Replace the air bag control
B1003 PASSENGER FRONTAL unit (refer to 52B/77 )
AIRBAG DEPLOYED
Airbag deployment
B1004 DRIVER PRETENSIONER DE-
PLOYED
DEPLOYED
B1025 DRIVER FRONT AIRBAG CON- Incorrect ACU unit installed to
FIGURATION FAULT vehicle. Check the correct part
B102A PASSENGER FRONT AIRBAG number and the model variant
CONFIGURATION FAULT Airbag configura- with supplier.
B1035 DRIVER PRETENSIONER CON- tion
FIGURATION FAULT
B103A PASSENGER PRETENSIONER
CONFIGURATION FAULT
Air bag control unit Do not attempt to troubleshoot
B1013 ACU INTERNAL ERROR
internal error any air bag control unit internal
B1001 EOL MODE - CRASH INHIBIT errors. Replace the air bag con-
ACU firing disable trol unit (refer to 52B/77 )

FRONT AIRBAG (DRIVER'S SIDE) WCH52BTSHOT11002
DOIMC52BR10001
INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE

Code No. B1021, B1022, B1023, B1024 Front Airbag
Probable cause
(Driver's side)
• Malfunction of clock spring.
These diagnosis codes are output if there is abnormal • Partial disconnection due to incorrect
resistance between the input terminals of the driver's clock spring neutral position.
side airbag module (squib). • Malfunction of wiring harnesses or con-
nectors.
The trouble causes for each diagnosis code number are • Malfunction of front airbag – driver's
as follows: side module (squib).
• Malfunction of SRS-ECU
Fault
PADT-II Display Trouble Causes
Code
• Short in driver's airbag module (squib)
B1021 Driver front airbag short circuit to ground
harness leading to the earth
B1022 Driver front airbag short circuit to battery
harness leading to the power supply
B1023 Driver front airbag short circuit or harness short
• Short in clock spring

Fault
PADT-II Display Trouble Causes
Code
• Open circuit in driver's airbag module
(squib) or open harness
• Open circuit in clock spring
• Disconnected driver's airbag module
B1024 Driver front airbag open circuit
(squib) connector
• Partial disconnection due to incorrect
clock spring neutral position
• Malfunction of connector contact
INSPECTION PROCEDURE
Step Instruction Condition Next State
1 Check clock spring (refer to 52B/82 ) NG REPLACE
OK Go to 3
2 PADT Diagnose Code NO
PADT Diagnose Code
• Reconnect floor harness connector for airbag control Go to 3

unit YES
• Reconnect the (-) battery terminal
• Erase diagnose code (fault code)
• OK : Fault code deleted
Are code no. B1021, B1022, B1023 or B1024 output?
Check the following connector: E-09 for continuity (refer NG REPAIR
3 to page continuity inspection) OK Replace the
SRS-ECU
Check the following connectors: C-13, D-09a, D-14 (refer NG REPAIR
4 to page continuity inspection) OK Go to 5
Check trouble symptoms NG Go to 6
5
OK STOP
Check the harness wire between the clock spring and SRS- NG REPAIR
6 ECU OK Go to 7
Replace SRS-ECU NG REPLACE
7
OK STOP

CONTINUITY INSPECTION
Instructions Condition Next State
NG Repair
1
OK go to 2
DOIGC13AR03129
Check E-09 and D-14 connectors for proper condition and
mating.
NG Go to 3
2
OK go to 5
DOIMC52BR07041
Disconnect E-09 and D-14 connectors. Check for continuity
between E-09 pin no. 2 and D-14 pin no. 2.
OK: Continuity
NG Repair
3
OK go to 4
DOIGC13AR03129
Check D-09a and C-13 connectors for proper condition and
mating.

DOIMC52BR07042
Disconnect D-09a connector. Check for continuity between E-
09 pin no. 2 and D-09a pin no. 1.
OK: Continuity
4 NG Repair
DOIMC52BR07043
Check for continuity between C-13 pin no. 10 and D-09a pin
no. 1.
OK: Continuity
DOIMC52BR07044
Check for continuity between D-14 pin no. 2 and D-09a pin
no. 1.
OK: Continuity


NG Repair
5
OK go to 6
DOIGC13AR03129
Check D-14 and C-13 connectors for proper condition and
mating.
NG go to 7
6
OK go to 8
DOIMC52BR07045
Check for continuity between E-09 pin no. 1 and D-14 pin no.
1.
OK: Continuity

DOIMC52BR07046
Disconnect C-13 connector. Check for continuity between E-
09 pin no. 1 and C-13 pin no. 9.
OK: Continuity
7 NG Repair
DOIMC52BR07047
Check for continuity between C-13 pin no. 9 and D-09a pin
no. 2.
OK: Continuity
DOIMC52BR07048
Check for continuity between D-09a pin no. 2 and D-14 pin
no. 1.
OK: Continuity
After checking that continuity in the harnesses are ok or recti-
8 OK Stop
fied, proceed to Fault Code Inspection.

FAULT CODE INSPECTION WCH52BTSHOT11003
FAULT CODE B1021: DRIVER FRONT AIRBAG SHORT CIRCUIT TO GOUND

Repair Instructions Condition Next State
NG Go to 9
1
OK Go to 2
DOIMC52BR07074
Check continuity between E-09 pin no. 11 and pin no. 2 to check
for leakage to ground.
OK: No continuity
NG Go to 9
2
OK Go to 3
DOIMC52BR07075
Check continuity between C-13 pin no. 10 and E-09 pin no. 11 for
leakage to ground.
OK: No continuity


NG Go to 9
3
OK Go to 4
DOIMC52BR07071
Check continuity between D-09a pin no. 1 and E-09 pin no. 11 for
leakage to ground.
OK: No continuity
NG Go to 9
4
OK Go to 5
DOIMC52BR07050
Check continuity between D-14 pin no. 2 and E-09 pin no. 11 for
leakage to ground.
OK: No continuity
NG Go to 9
5
OK Go to 6
DOIMC52BR07072
Check continuity between E-09 pin no. 11 and pin no. 1 to check
OK: No continuity


NG Go to 9
6
OK Go to 7
DOIMC52BR07073
Check continuity between C–13 pin no. 9 and E-09 pin no. 11 to
check for leakage to ground.
OK: No continuity
NG Go to 9
7
OK Go to 8
DOIMC52BR07076
Check continuity between D-09a pin no. 2 and E-09 pin no. 11 to
OK: No continuity
NG Go to 9
8
OK Go to 10
DOIMC52BR07049
Check continuity between D-14 pin no. 1 and E-09 pin no. 11 to
OK: No continuity


A wiring fault (leakage to ground) is present at the respective
9 floor harness /dash harness / clock spring. Repair the damaged OK STOP
line or if necessary, replace the harness.
10 Replace Airbag Control Unit (Refer to 52B/77 ). OK STOP
FAULT CODE B1022: DRIVER FRONT AIRBAG SHORT CIRCUIT TO BATT
NG go to 9
1
OK go to 2
DOIMC52BR07069
• Reconnect all disconnected driver front airbag connectors.
• Reconnect the negative (-) battery terminal.
• Switch the ignition ON.
Check leakage to plus between E-09 pin no. 1 and pin no. 2
OK : 0 V
NG go to 9
2
OK go to 3
DOIMC52BR07070
• Check leakage to plus between E-09 pin no. 11 and C-13 pin
no. 10.
OK : 0 V


NG go to 9
3
OK go to 4
DOIMC52BR07071
• Check leakage to plus between D-09a pin no. 1 and E-09
pin no. 11
OK : 0 V
NG go to 9
4
OK go to 5
DOIMC52BR07050
Check leakage to plus between D-14 pin 2 and E-09 pin no. 11
OK : 0 V
NG go to 9
5
OK go to 6
DOIMC52BR07072
Check leakage to plus between E-09 pin no. 1 and no. 11
OK : 0 V


NG go to 9
6
OK go to 7
DOIMC52BR07073
Check leakage to plus between C-13 pin no. 9 and E-09 pin no.
11
OK : 0 V
NG go to 9
7
OK go to 8
DOIMC52BR07076
Check leakage to plus between D-09a pin no. 2 and E-09 pin
no. 11
OK : 0 V
NG go to 9
8
OK go to 10
DOIMC52BR07049
Check leakage to plus between D-14 pin no. 1 and E-09 pin no.
11
OK : 0 V


A wiring fault (leakage to plus line) is present at the respective
dash harness / floor harness / clock spring. Repair the damaged
9 CAUTION OK STOP
The battery negative (-) terminal MUST be disconnected after
leakage to plus inspection and before the repair work is con-
ducted.
10 Replace Air Bag Control Unit (Refer to 52B/77 ). OK STOP
FAULT CODE B1023: DRIVER FRONT AIRBAG SHORT CIRCUIT
NG go to 5
1
OK go to 2
DOIMC52BR07069
Check for continuity between E-09 pin no. 1 and pin no. 2.
OK: Continuity
NG go to 5
2
OK go to 3
DOIMC52BR07077
Disconnect C-13 connector. Check for continuity between pin no.
9 and pin no. 10
OK: No continuity


NG go to 5
3
OK go to 4
DOIMC52BR07078
Check for continuity between D-09a pin no. 1 and pin no. 2.
OK: No continuity
NG go to 5
4
OK go to 6
DOIMC52BR07093
Check for continuity between D-14 pin no. 1 and pin no. 2.
OK: No continuity
Short circuit is present in the floor harness / dash harness / clock
5 spring. Repair the damaged line or if necessary, replace the har- OK STOP
ness.
6 Replace the Airbag Control Unit (Refer to 52B/77 ). OK STOP
FAULT CODE B1024: DRIVER FRONT AIRBAG OPEN CIRCUIT
Replace the Airbag Control Unit (Refer to 52B/77 ). OK Stop


REMOVAL OF NEGATIVE (-) BATTERY CABLE
FROM THE BATTERY
1. Disconnect the negative battery cable and
tape the terminal.
CAUTION
Wait at least 5 minutes after disconnecting
the battery cable before doing any further
work.
DOIMC015R07017
Symbol Description
A Battery cable
B Insulating tape
C Battery
2. Disconnect the following connectors :
• Disconnect safety connector
2.1 Squib connector for driver airbag.
2.2 Dash harness connector for driver front
airbag module and the floor harness
connector for side airbag modules.
2.3 Squib connector for both pre-tensioner
seat belts.
2.4 Floor harness connector for Airbag
Control Unit and RSU sensor.
2.5 As a safety precaution, remove the
airbag module and place it facing up-
ward on a clean area before proceeding
with other tasks.
DOIJC52BR04013
Symbol Description
A Front airbag module
WARNING
• Never connect battery or turn the ignition
switch ON while removing or installing the
airbag module.
• Never use ohmmeter or other current-carry-
ing devices to test the airbag module.
DOIMC52BR07039

POST-INSTALLATION
FRONT DRIVER AIRBAG
CONNECT / RECONNECT THE FOLLOWING (Upon
completion of the repair works for system
check):
Airbag simulator to all the harness connectors
for airbag. (Driver, passenger and both side
airbags).
• Airbag simulator to both pre-tensioner seat
belts.
• Connector to Airbag Control Unit.
• Battery (-) terminal.
• Turn the ignition key to “ON” position. Then
check system on combination meter SRS in-
dicator lamp if ⇒ NO flash blink ⇒ The airbag
system is “OK” and airbag connector can be
reconnect to normal. If the indicator lamp
still flashes, refer to workshop manual on
SRS troubleshooting and repair procedure.
Symbol Description
A Airbag simulator and sub har-
ness
B Body harness connector for side
airbag/pre-tensioner
DOIJC52BR04126
C Airbag control unit (SRS ECU)
D Connector Airbag control unit
(SRS ECU)
E Lock lever
INSPECTION
DRIVER FRONT AIRBAG MODULE
If any improper parts were found during the
following inspection, replace the driver airbag
module with a new one. All airbags removed
from the vehicle must be shipped to designated
supplier for destruction. This should not be
handled by unauthorized personnel.
1. Check hard cover for dents, cracks or deform-
ities.
2. Check the airbag module for denting, crack-
DOIJC52BR04013 ing or deformation.
3. Check hooks and connectors for damage,
terminals for deformities, and harness for
binds.
4. Check air inflator case for dents, cracks or
deformities.
CAUTION
Never attempt to measure the circuit resistance
of the airbag module (squib) even if you are us-
ing the specified tester. If the circuit resistance

is measured with a tester, airbag accident deploy-

ment will result in serious personal injury.
Symbol Description

FRONT AIRBAG (PASSENGER SIDE) WCH52BTSHOT11004
DOIMC52BR10002
PROBABLE CAUSES OF FAULT CODE

Fault Code PADT-II Display Probable Causes
Passenger Front Airbag Short Circuit Passenger Front Airbag
B1026
To Ground
Passenger Front Airbag Short Circuit • Squib connector not locked or
B1027 malfunction.
To Battery
• Wrong terminal location or elec-
B1028 Passenger Front Airbag Short Circuit
trical connectivity malfunction/con-
tact not good at:
• Connector dash harness to
passenger front airbag.
• Connector floor harness to
B1029 Passenger Front Airbag Open Circuit Airbag Control Unit.
• Open or short circuit at the har-
ness.
• Squib malfunction.
• Airbag Control Unit short circuit
or malfunction.

MODULE FAULT INSPECTION
Diagram / RepairInstructions Condition Next State
1. Reconnect floor harness connector for Airbag Control Unit NG go to 3
and RSU.
1 2. Reconnect the (-) battery terminal.
3. Using PADT-II Display, delete fault code. OK go to 2
OK: Fault code deleted
Replace Passenger Front Airbag module (Refer to page 52B/90
2 – Front Passenger Airbag module removal & installation in this OK Stop
supplement) and proceed to Post-Installation.
3 Proceed to Continuity Inspection. OK Stop
1 NG Repair
OK go to 2
DOIGC13AR03129
Check D–20 and E–09 connectors for proper condition and mating.
2 NG Go to 3
OK go to 5
DOIMC52BR10004
Disconnect E–09 and D–20 connectors. Check for continuity between
E–09 pin no. 4 and D–20 pin no. 1.
OK: Continuity
3 NG Repair

OK go to 4
DOIGC13AR03129
Check C–14 connector for proper condition and mating.
4
NG Repair
DOIMC52BR10005
Disconnect C–14 connector. Check for continuity between E–09 pin
no. 4 and C–14 pin no. 14.
OK: Continuity
OK go to 5
DOIMC52BR10006
Check for continuity between C–14 pin no. 14 and D–20 pin no. 1.
OK: Continuity
5 NG go to 6

OK go to 8
DOIMC52BR10007
Check for continuity between E–09 pin no. 3 and D–20 pin no. 2.
OK: Continuity
6 NG Repair
OK go to 7
DOIGC13AR03129
Check C–14 connectors for proper condition and mating.
7
NG Repair
DOIMC52BR10008
Disconnect C–14 connector. Check for continuity between E–09 pin
no. 3 and C–14 pin no. 13 .
OK: Continuity

OK go to 8
DOIMC52BR10009
Check for continuity between C–14 pin no. 13 and D–20 pin no. 2.
OK: Continuity
Reconnect C–14 connector.
8 After checking that continuity in the harnesses are ok or rec- OK Stop
tified, proceed to Fault Code Inspection.
FAULT CODE B1026: PASSENGER FRONT AIRBAG SHORT CIRCUIT TO GROUND

1 NG go to 2
OK go to 3
DOIMC52BR10014
Check continuity between E–09 pin no. 4 and E–09 pin no. 11 to check
OK: No continuity
2 NG Go to 6

OK go to 5
DOIMC52BR10011
• Disconnect C–14 connector.
Check continuity between C–14 pin no. 14 and E–09 pin no. 11 to
OK: No continuity
3 NG Go to 4
OK go to 7
DOIMC52BR10012
Check continuity between pin connector E–09 no. 3 and E–09 pin no.
11 to check for leakage to ground.
OK: No continuity
4 NG Go to 6

OK go to 5
DOIMC52BR10013
Check continuity between pin connector C–14 no. 13 and E–09 pin
no. 11 to check for leakage to ground.
OK: No continuity
5
OK Stop
DOIKC35BR03090
A wiring fault (leakage to ground) is present at the respective floor
harness. Repair the damaged line or if necessary, replace the harness.
6
OK Stop
DOIKC35BR03090
A wiring fault (leakage to ground) is present at the respective dash


7 Replace Airbag Control Unit (Refer to 52B/77 ). OK Stop
FAULT CODE B1027: PASSENGER FRONT A/BAG SHORT CIRCUIT TO BATT
1 NG go to 2
OK go to 3
DOIMC52BR10010
• Reconnect all disconnected passenger front airbag connectors.
Check leakage to plus between E–09 pin no. 4 and E–09 pin no. 11.
OK: Voltage reading OV
2 NG Go to 6
OK go to 5
DOIMC52BR10011
Check leakage to plus between C–14 pin no. 14 and E–09 pin no. 11.
3 NG Go to 4

OK go to 7
DOIMC52BR10012
4 NG Go to 6
OK go to 5
DOIMC52BR10013
Check leakage to plus between C–14 pin no. 13 and E–09 pin no. 11.


5
OK Stop
DOIKC35BR03090
A wiring fault (leakage to plus line) is present at the respective floor
CAUTION
The battery negative (-) terminal MUST be disconnected after leakage
to plus inspection and before the repair work is conducted.
6
OK Stop
DOIKC35BR03090
A wiring fault (leakage to plus line) is present at the respective dash
CAUTION
7 Replace Air Bag Control Unit (Refer to 52B/77 ). OK Stop
FAULT CODE B1028: PASSENGER FRONT AIRBAG SHORT CIRCUIT
1 NG Go to 2

OK Go to 5
DOIMC52BR10015
Check for continuity between E–09 pin no. 3 and E–09 pin no. 4.
OK: No continuity
2 NG Go to 4
OK Go to 3
DOIMC52BR10016
Disconnect C–14 connector. Check for continuity between C–14 pin
no. 13 and C–14 pin no. 14.
OK: Continuity
3
OK Stop
DOIKC35BR03090
Short circuit is present at the floor harness. Repair the damaged line
or if necessary, replace the harness.


4
OK Stop
DOIKC35BR03090
Short circuit is present at the dash harness. Repair the damaged line
5 Replace the Airbag Control Unit (Refer to 52B/77 ). OK Stop
FAULT CODE B029: PASSENGER FRONT AIRBAG OPEN CIRCUIT
FROM THE BATTERY
tape the terminal.
CAUTION
work.
DOIMC015R07017
Symbol Description
A Battery cable
B Insulating tape
C Battery
2.2 Dash harness connector for passenger
front airbag module and the floor har-
ness connector for side airbag modules.
seat belts.

2.5 As a safety precaution, remove the

airbag module and place it facing up-
ward on a clean area before proceeding
with other tasks.
Symbol Description
WARNING
airbag module.
DOIJC52BR01024

DOIMC52BR07039
POST-INSTALLATION
PASSENGER FRONT AIRBAG
check):
1. Airbag simulator to all the harness connect-
ors for airbag. (Driver, passenger and both
side airbags).
2. Airbag simulator to both pre-tensioner seat

belts.
3. Connector to Airbag Control Unit and Re-

mote Sensing Unit.
4. Battery (-) terminal.
Symbol Description
A Airbag simulator and sub
harness
B Body harness connector for
side airbag/pre-tensioner
C Airbag control unit (SRS
DOIJC52BR04126
ECU)
D Connector Airbag control
unit (SRS ECU)
E Lock lever

5. Turn the ignition key to “ON” position. Then

dicator lamp if ⇒ “WARNING LAMP OFF” ⇒
The airbag system is “OK” and airbag con-
nector can be reconnect to normal. If the in-
dicator “STAYS ON”, refer to workshop
manual on SRS troubleshooting and repair
procedure.
Symbol Description
A Ignition key to “ON” posi-
DOIMC52BR07010
tion
INSPECTION
PASSENGER FRONT AIRBAG MODULE
1. If any improper parts were found during the
following inspection, replace the passenger
airbag module with a new one. All airbags
removed from the vehicle must be shipped
to designated supplier for destruction. This
should not be handled by unauthorized
personnel.
CAUTION
Never attempt to measure the circuit resist-
DOIJC52BR01024
ance of the airbag module (squib) even if
you are using the specified tester. If the cir-
cuit resistance is measured with a tester, air
bag accident deployment will result in seri-
ous personal injury.
ities.
2. Check the air bag module for denting,
cracking or deformation.
binds.
deformities.

PRE TENSIONER (DRIVER'S SIDE) WCH52BTSHOT11006
DOIMC52BR07062
INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE

Code No. B1031, B1032, B1033 or B1034 Pre Tensioner (Driver's
Probable Cause
side)
These diagnosis code are output if there is abnormal resistance • Malfunction of wiring harnesses
between the input terminals of the driver's Pre-Tensioner or connectors
• Malfunction of driver's pre-ten-
The trouble causes for each diagnosis code Nos are as follows:
sioner

Driver Pre Tensioner Short Circuit To • Short in driver's pre-tensioner
B1031
Battery harness leading to power supply
Driver Pre Tensioner Short Circuit To • Short in driver's pre-tensioner
B1032
Ground harness leading to earth
• Open circuit in driver's pre-tension-
er or open harness
• Malfunction of driver's pre-ten-
B1033 Driver Pre Tensioner Open Circuit
sioner
• Malfunction of connector contact


• Short in driver's pre-tensioner or
B1034 Driver Pre Tensioner Short Circuit
harness short
Step Instruction Condition Next Step
PADT Diagnose Code NO Go to 2
• Reconnect floor harness connector for SRS-ECU
1
• Using PADT-II, erase fault code
Are code no. B1031, B1032, B1033 or B1034 output? YES Go to 4
Check the following connector: E-09 and E-16 (refer to NG REPAIR
2
Continuity Inspection section) OK Go to 3
Check trouble symptoms (refer to Fault Code Inspection NG Go to 5
3
section) OK STOP
Replace driver's pre-tensioner module (Refer to page OK STOP
4
52B/95 )
5 Replace SRS-ECU OK STOP
Instruction Condition Next State
NG REPAIR
1
OK go to 2
DOIGC13AR03129
Check E-16 and E-09 connectors for proper condition and
mating.


NG REPAIR
2
OK go to 3
DOIMC52BR07054
Disconnect E-09 and E-16 connectors. Check for continuity
between E-09 pin no. 8 and E-16 pin no. 2.
OK: Continuity
NG REPAIR
OK go to 4
DOIMC52BR07055
Check for continuity between E-09 pin no. 9 and E-16 pin no.
1.
OK: Continuity
4 OK STOP

FAULT CODE B1031: DRIVER PRE TENSIONER SHORT CIRCUIT TO GROUND

NG go to 3
1
OK go to 2
DOIMC52BR07058
Check connector E-09 between pin no. 9 and pin no. 11 for leakage
to ground checking.
OK: No continuity
NG Go to 3
2
OK go to 4
DOIMC52BR07059
Check connector E-09 beween pin no. 8 and pin no. 11 for leakage
to ground checking.
OK: No continuity
A wiring fault (leakage to ground) is present at the respective
3 floor harness. Repair the damaged line or if necessary, replace OK STOP
the harness.

FAULT CODE B1032: DRIVER PRE TENSIONER SHORT CIRCUIT TO BATTERY

NG go to 3
1
OK go to 2
DOIMC52BR07056
• Reconnect all driver pretensioner connectors.
to plus checking.
OK : 0 voltage
NG go to 3
2
OK go to 4
DOIMC52BR07057
to plus checking
OK : 0 voltage
A wiring fault (leakage to plus line) is present at the respective
floor harness. Repair the damaged line or if necessary, replace
the harness.
3 CAUTION OK STOP
The battery negative (-) terminal MUST be disconnected after
leakage to plus inspection and before the repair work is conduc-
ted.

FAULT CODE B1033: DRIVER PRE TENSIONER SHORT CIRCUIT

NG Go to 2
1
OK Go to 3
DOIMC52BR07060
Check connector E-09 pin no. 8 and pin no. 9 for short circuit.
OK: No continuity
Short circuit is present at the floor harness. Repair the damaged
2 OK STOP
FAULT CODE B1034: DRIVER PRE TENSIONER OPEN CIRCUIT
FROM THE BATTERY
tape the terminal.
CAUTION
work.
DOIMC015R07017
Symbol Description
A Battery cable
B Insulating tape
C Battery
– Squib connector for driver airbag.
– Dash harness connector for driver front
airbag module and the floor harness
connector for side airbag modules.
– Squib connector for both pre-tensioner
seat belts.
– Floor harness connector for Airbag
Control Unit.

3. As a safety precaution, remove the airbag

module and place it facing upward on a
clean area before proceeding with other
tasks.
Symbol Description
DOIJC52BR04013
WARNING
– Never connect battery or turn the ignition
airbag module.
– Never use ohm meter or other current-carrying
devices to test the airbag module.
DOIMC52BR07039
POST-INSTALLATION
DRIVER PRE TENSIONER
check):
• Airbag simulator to all the harness connect-
side airbags).
belts.
• Connector to Airbag Control Unit.
• Turn the ignition key to “ON” position. Then
dicator lamp if ⇒ NO flash blink ⇒ The airbag
Symbol Description
Airbag simulator and sub
A
harness
Body harness connector for
B
DOIJC52BR04126

Symbol Description
Airbag Control Unit (SRS
C
ECU)
Connector Airbag Control
D
Unit (SRS ECU)
E Lock lever
INSPECTION
DRIVER SIDE AIRBAG MODULE
If any improper parts were found during the
following inspection, replace the driver pre ten-
sioner module with a new one. All airbags re-
moved from the vehicle must be shipped to des-
ignated supplier for destruction. This should not
be handled by unauthorized personnel.
CAUTION
of the airbag module (squib) even if you are us-
DOIJC52BR04013
ing the specified tester. If the circuit resistance
is measured with a tester, air bag accident de-
ployment will result in serious personal injury.
ities.
binds.
deformities.
Symbol Description

PRE TENSIONER (PASSENGER SIDE) WCH52BTSHOT11008
DOIMC52BR10003
PROBABLE CAUSES OF FAULT CODE

Passenger Pre Tensioner Short Circuit Passenger Pretensioner
B1036
To Battery
Passenger Pre Tensioner Short Circuit • Squib connector not locked or
B1037 malfunction.
To Ground
• Wrong terminal location or elec-
B1038 Passenger Pre Tensioner Short Circuit
trical connectivity malfunction/con-
tact not good at connector har-
ness from Airbag Control Unit to
passenger pretensioner.
B1039 Passenger Pre Tensioner Open Circuit • Open or short circuit at the har-
ness.
• Squib malfunction.
• Airbag Control Unit short circuit
or malfunction.

Step Instruction Condition Next Step
PADT-II Diagnose Code NO Go to 2
• Reconnect floor harness connector for SRS-ECU
1
• Using PADT-II, erase fault code
Are code no. B1036, B1037, B1038 or B1039 output? YES Go to 4
Check the following connector: E-09 and E-19 (refer to NG REPAIR
2
Continuity Inspection section) OK Go to 3
Check trouble symptoms (refer to Fault Code Inspection NG Go to 5
3
section) OK STOP
Replace Passenger's pre-tensioner module (Refer to OK STOP
4
page 52B/95 )
5 Replace SRS-ECU OK STOP
NG REPAIR
1
OK go to 2
DOIGC13AR03129
Check E-19 and E-09 connectors for proper condition and
mating.
NG REPAIR
2
OK go to 3
DOIMC52BR07054
Disconnect E-09 and E-16 connectors. Check for continuity
between E-09 pin no. 30 and E-19 pin no. 2.
OK: Continuity


NG REPAIR
OK go to 4
DOIMC52BR07055
Check for continuity between E-09 pin no. 7 and E-19 pin no.
1.
OK: Continuity
4 OK STOP
FAULT CODE B1036: PASSENGER PRE TENSIONER SHORT CIRCUIT TO GROUND

1 NG go to 3
OK go to 2
DOIMC52BR10017
• Reconnect all passenger pre tensioner connectors.
2 NG Go to 3

OK go to 4
DOIMC52BR10018
3
OK Stop
DOIKC35BR03090
A wiring fault (leakage to plus line) is present at the respective floor
CAUTION
4
OK Stop
Replace Airbag Control Unit (Refer to 52B/77 ).
FAULT CODE B1037: PASSENGER PRE TENSIONER SHORT CIRCUIT TO BATT
1 NG go to 3

OK go to 2
DOIMC52BR10017
OK: No continuity
2 NG Go to 3
OK go to 4
DOIMC52BR10018
OK: No continuity
3
OK Stop
DOIKC35BR03090
A wiring fault (leakage to ground) is present at the respective floor


4 Replace Airbag Control Unit (Refer to 52B/77 ). OK Stop
FAULT CODE B1038: PASSENGER PRE TENSIONER SHORT CIRCUIT
1 NG Go to 2
OK Go to 3
DOIMC52BR10019
Check for continuity between E–09 pin no. 5 and E–09 pin no. 6.
OK: No continuity
2
OK Stop
DOIKC35BR03090
Short circuit is present at the floor harness. Repair the damaged line
3
OK Stop
Replace the Airbag Control Unit (Refer to 52B/77 ).
FAULT CODE B1039: PASSENGER PRE TENSIONER OPEN CIRCUIT
Diagram / Repair Instructions Condition Next State


FROM THE BATTERY
tape the terminal.
CAUTION
work.
DOIMC015R07017
Symbol Description
A Battery cable
B Insulating tape
C Battery
2.2 Dash harness connector for passenger
ness connector for side airbag modules.
seat belts.
2.5 As a safety precaution, remove the air
bag module and place it facing upward
on a clean area before proceeding with
other tasks.
DOIJC52BR01024
Symbol Description
A Passenger front airbag mod-
ule
WARNING
airbag module.
• Never use ohm meter or other current-carry-
DOIMC52BR07039

POST-INSTALLATION
PASSENGER PRETENSIONER
check):
1. Airbag simulator to all the harness connect-
side airbags).
2. Airbag simulator to both pre-tensioner seat

belts.
3. Connector to Air bag Control Unit and Re-

mote Sensing Unit.
4. Battery (-) terminal.
Symbol Description
harness
C Airbag control unit (SRS
DOIJC52BR04126
ECU)
D Connector Airbag control
unit (SRS ECU)
E Lock lever
dicator lamp if ⇒ “WARNING LAMP OFF” ⇒
The airbag system is “OK” and airbag con-
nector can be reconnect to normal. If the in-
dicator “STAYS ON” , refer to workshop
manual on SRS troubleshooting and repair
procedure.
Symbol Description
DOIMC52BR07010
tion
INSPECTION
PASSENGER PRE TENSIONER MODULE
1. If any improper parts were found during the
following inspection, replace the passenger
pre tensioner module with a new one. All
airbags removed from the vehicle must be
shipped to designated supplier for destruc-
tion. This should not be handled by unauthor-
ized personnel.

CAUTION
ance of the airbag module (squib) even if
cuit resistance is measured with a tester,
airbag accident deployment will result in
serious personal injury.
ities.
3. Check the airbag module for denting, crack-
ing or deformation.
binds.
deformities.
POWER AND METER COMBINATION WCH52BTSHOT11010
Code No. B1011, B1012, B1091 or B1092 Probable Causes

• Malfunction of wiring har-
nesses or connectors
• Malfunction of combination
This diagnosis code is output if malfunction on power and meter meter
combination line • Open or short circuit at power
line

B1011 Battery low voltage • Battery weak
• Battery not within specification
• Improper mating of connectors
B1012 Battery high voltage
• Open or short circuit at power line
• Damaged Air Bag Control Unit
• Short circuit to ground at harness
B1091 Warning lamp short circuit to Ground or component
• Short circuit to battery at harness
B1092 Warning lamp short circuit to Battery or component
FAULT CODE INSPECTION
FAULT CODE B1011: BATTERY LOW VOLTAGE
• Ensure that the battery is properly mated with the NG go to 2
connectors and that no dirt or dust are at the con-
1 tact surfaces.
• Delete fault code OK STOP
OK : No fault code


• Check the battery voltage using the multimeter NG go to 3
2 • Reconnect the negative (-) battery terminal.
OK : Voltage reading - 10.5 – 12 V OK go to 4
3 Recharge or if necessary, replace the battery OK STOP
Check the following connectors for proper condition NG go to 5
and mating:
• E-09
4 • C-13
• D-06 OK STOP
Delete fault code
OK : No fault code
• Open the harness to visually detect any physical NG go to 6
defect, short circuit or open circuit on the power
line.
5
• Repair or if necessary, replace the damaged line. OK STOP
• Delete fault code
OK : No fault code
FAULT CODE B1012: BATTERY HIGH VOLTAGE
• Ensure that the battery is properly mated with the NG go to 2
connectors and that no dirt or dust are at the con-
1 tact surfaces.
• Delete fault code OK STOP
OK : No fault code
• Check the battery voltage using the multimeter NG go to 3
2 • Reconnect the negative (-) battery terminal.
OK : Voltage reading - 10.5 – 12 V OK go to 4
3 Recharge or if necessary, replace the battery OK STOP
Check the following connectors for proper condition NG go to 5
and mating:
• E-09
4 • C-13
• D-06 OK STOP
Delete fault code
OK : No fault code
• Open the harness to visually detect any physical NG go to 6
defect, short circuit or open circuit on the power
line.
5
• Repair or if necessary, replace the damaged line. OK STOP
OK : No fault code

FAULT CODE B1091: WARNING LAMP SHORT CIRCUIT TO GROUND

NG go to 2
1
OK go to 11
DOIMC52BR07065
• Disconnect E-09 connector.
• Check for continuity between E-09 pin no. 10 and pin no. 11
• OK : Continuity
NG Go to 3
2
OK go to 6
DOIMC52BR07066
• Disconnect C-13 and E-09 connectors.
• Check C-13 pin no. 7 and E-09 pin no. 11.
• OK : No continuity
NG go to 4
3
OK go to 7
DOIMC52BR07067
• Disconnect D-06 connector.
• Check for continuity between D-06 pin no. 14 and E-09 pin
no. 11


NG go to 5
4
OK go to 8
DOIMC52BR07068
• Check for continuity between D-06 pin no. 6 and E-09 pin no.
11
NG go to 10
5
OK go to 9
DOIMC52BR07064
• Disconnect D-06 and E-09 connectors.
• Check for continuity between D-06 pin no. 4 and E-09 pin no.
11.
• A wiring fault (leakage to ground) is present at the wire con-
necting E-09 and C-13 connectors.
6 • Repair the damaged line or if necessary, replace fuse no. 16 OK STOP
(in instrument panel fuse box).
necting D-06 and C-13 connectors.
necting D-06.


necting D-06 and D-09a connectors.
necting fuse no. 16 and D-09a connectors.
FAULT CODE B1092: WARNING LAMP SHORT CIRCUIT TO BATTERY
NG go to 2
1
OK go to 5
DOIMC52BR07065
• Disconnect E-09 connector.
• Check leakage to battery between E-09 pin no. 10 and E-09
pin no. 11
• OK : No voltage
NG Go to 4
2
OK go to 3
DOIMC52BR07066
• Disconnect C-13 and E-09 connectors.
• Check leakage to battery between C-13 pin no. 7 and E-09 pin
no. 11.
• OK : No voltage


• A wiring fault (leakage to battery) is present at the wire con-
necting E-09 and C-13 connectors.
3 OK STOP
• Repair the damaged line or if necessary, replace the harness.
• A wiring fault (leakage to plus line) is present at the wire
connecting D-06 and C-13 connectors.
4 OK STOP
• Repair the damaged line or if necessary, replace the harness.
FROM THE BATTERY
tape the terminal.
CAUTION
work.
DOIMC015R07017
Symbol Description
A Battery cable
B Insulating tape
C Battery
Disconnect safety connector
• Squib connector for driver airbag.
• Dash harness connector for passenger
ness connector for side air bag modules.
• Squib connector for both pre-tensioner
seat belts.
• Floor harness connector for Air Bag
Control Unit.
• As a safety precaution, remove the air
bag module and place it facing upward
DOIJC52BR04013 on a clean area before proceeding with
other tasks.
Symbol Description
3. Connect the airbag simulators to the follow-
ing connectors:
• Squib connector for driver airbag
• Dash and floor harness connectors for
passenger front airbag module (if so
equipped)
• Squib connectors for both pre-tensioner
seat belts

WARNING
airbag module.
DOIMC52BR07039
POST-INSTALLATION
check):
• Airbag simulator to all the harness connect-
side airbags).
belts.
• Connector to Air Bag Control Unit.
Symbol Description
harness
C Airbag control unit (ECU)
D Connector side airbag
E Lock lever
DOIJC52BR04126

dicator lamp if ⇒ NO flash blink⇒ The airbag
Symbol Description
tion.
DOIMC52BR07010

/ 68 SRS MAINTENANCE
SRS MAINTENANCE WCH52BMAINT11001
The SRS MUST be inspected by an authorized dealer 10 years after the date of vehicle registration
SRS WARNING LAMP CHECK
DOIMC52BR07004
Turn the ignition switch to the “ON” position. Does the SRS warning lamp illuminate for about 7
seconds, turn off and the remain extinguished for at least 5 seconds? If YES, SRS system is functioning
properly. If NO, consult page 52B/10
SRS COMPONENT VISUAL CHECK
DOIMC015R07017
Turn the ignition switch to the “LOCK” position, disconnect the negative (-) battery cable and tape
the terminal
Symbol Description
A Battery cable
B Insulating tape
C Battery
CAUTION
Wait at least 5 minutes after disconnecting the battery cable before doing any further work (refer
to 52B/5 )

SRS MAINTENANCE / 69
SRS Control Unit (SRS-ECU)
DOIMC52BR07011
1. Check SRS-ECU case and brackets for dents, cracks, deformation or rust.
CAUTION
The SRS may not active if the SRS-ECU is not installed properly, which could result in serious injury
1
or death to the vehicle's driver or front passenger
2. Check connector for damage, and terminals for deformation or rust. Replace SRS-ECU if it fails
visual check (refer to 52B/77 )
Air Bag Modules, Steering Wheel and Clock Spring
1. Remove the airbag modules, steering wheel and clock spring (refer to 52B/82 )
CAUTION
The removed air bag module should be stored in a clean, dry place with the cover face up.
2. Check cover for dents, cracks or deformation.
DOIMC52BR07012
3. Check connector for damage, terminals deformities and harness for binds.
Symbol Description
A Inflator case
B Terminal
4. Check air bag inflator case for dents, cracks or deformities.
5. Check harness and connectors for damage and terminals for deformation.
NOTE:
1: if fitted

/ 70 SRS MAINTENANCE
DOIMC52BR07013
6. Check clock spring connectors and protective tube for damage, and terminals for deformation.
Symbol Description
A Window
B Mating marks
C Harness horn
D Harness SRS
7. Visually check the clock spring case for damage.
8. Align the mating marks of the clock spring and, after turning the vehicle's front wheels to straight-
ahead position, install the clock spring to the column switch.
Mating Mark Alignment
Turn the clock spring to align the mating marks and window indicates at the position.Ensure white
colour roller appear at clock spring window.
CAUTION
If the clock spring's mating mark is not properly aligned, the steering wheel may not be completely
rotational during a turn, or the flat cable within the clock spring may be served, obstructing
normal operation of the SRS and possibly leading to serious injury to the vehicle's driver or front
1
passenger
9. Install the steering column covers, steering wheel and the air bag module.
10. Check steering wheel for noise, binds of difficult operation.
11. Check steering wheel for excessive free play. REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS
THAT INSPECTION (refer to 52B/82 )
CAUTION
The SRS may not activate if any of the above components is not installed properly, which could result
in serious injury or death to the vehicle's driver or front passenger.

SRS MAINTENANCE / 71
INSTRUMENT PANEL WIRING HARNESS/FLOOR WIRING HARNESS
DOIMC52BR07002
1. Check connector for poor connection.

2. Check harness for binds, connector for damage and terminals for deformation.
Symbol Description
A Passenger airbag* (if so equipped)
B Instrument panel wiring harness
C Driver airbag
D Floor wiring harness
E SRS ECU
NOTE :
REPLACE ANY CONNECTORS OR HARNESS THAT FAIL THE VISUAL INSPECTION (Refer to page
52B/5 ).
CAUTION
The SRS may not activate if SRS harnesses or connectors are damaged or improperly connected,
which could result in serious injury or death to the vehicle's driver or front passenger.
POST INSTALLATION INSPECTION
DOIJC52BR04011
Reconnect the negative battery terminal. Turn the ignition switch to the “ON” position. Does the SRS
warning lamp illuminate for about 7 seconds, turn off and then remain extinguished for at least 5
seconds? If YES, SRS system is functioning properly. If NO, refer to page 52B/10 )

/ 72 POST COLLISION DIAGNOSIS
POST COLLISION DIAGNOSIS WCH52BPOSTC11001
To inspect and service the SRS after collision (whether or not the air bag have deployed), perform the
following steps
SRS – ECU MEMORY CHECK
1. Connect the PADT to the diagnosis connector (16–pins)
CAUTION
Make a certain that the ignition switch is OFF when the PADT is connected or disconnected.
2. Read and note down all the displayed diagnosis codes (refer to 52B/10 )
NOTE
If the battery power supply has been disconnected or distrupted by the collision, the PADT cannot
communicate with the SRS-ECU. Inspect and, if necessary repair the body wiring harness before
proceeding further.
3. Read the data list (fault duration and how many times memories are erased) using the PADT.
4. Erase the diagnosis codes and after waiting 5 seconds or more read and note down all displayed
diagnosis code (refer to 52B/10 )
REPAIR PROCEDURE
When Air bag Deploy or Seat Belt Pre-Tensioner Operates in a Collision
1. Replace the following parts with new ones
• SRS-ECU (refer to 52B/77 )
• Driver's side air bag module (refer to 52B/82 )
• Seat belt with pre-tensioner (refer to 52B/95 )
2. Check the following parts and replace if there are any malfunctions
• Clock spring (refer to 52B/77 )
• Steering wheel, steering column and intermediate joint
1. Check wiring harness and connectors for damage, and terminals for deformation.
2. Install air bag module to check fit or alignment with steering wheel.
3. Check steering wheel for noise, binds or difficult opertaion and excessive free play.
3. Check harnesses for binding, connectors for damage, poor connections and terminal for deform-
ation (refer to Instrument panel wiring harness/floor harness section)
When Seat Belt Pre-Tensioner Operates in a Collision
1. Replace the following parts
• SRS-ECU (refer to 52B/77 )
• Seat belt with pre-tensioner (refer to 52B/95 )
2. Check harnesses for binding, connectors for damage, poor connections and terminal for deform-
ation (refer to Instrument panel wiring harness/floor wiring harness section)
When Air Bag or Seat Belt Pre-Tensioner Does Not Deploy in Low Speed Collision
Check the SRS components and seat belt with pre-tensioner. If the SRS components and seat belt with
pre-tensioner are showing any visible damage such as dents, cracks, or deformation, replace them
with new ones. Concerning parts removed for inspection, replacement with new parts and cautionary
points for working, refer to appropriate INDIVIDUAL COMPONENTS SERVICE, 52B/73 )

INDIVIDUAL COMPONENT SERVICE / 73
DOIMC52BR07011
1. SRS ECU
1.1 Check SRS-ECU case and brackets for dents, cracks or deformation.
1.2 Check connector for damage, and terminals for deformation.
2. Air Bag Modules
2.1 Check over for dents, cracks or deformation.
2.2 Check connector fro damage, terminals deformities, and harness for binds.
2.3 Check air bag inflator case for dents, cracks or deformities.
2.4 Install air bag module to steering wheel to check fit or alignment with the wheel.
3. Clock Spring
3.1 Check clock spring connectors and protective tubes for damage, and terminals for deformation.
3.2 Visually check the case for damage.
4. Steering Wheel, Steering Column and Intermediate Joint
4.1 Check wiring harness and connectors for damage, and terminals for deformation.
4.2 Install air bag module to check fit or alignment with steering wheel.
4.3 Check steering wheel for noise, binds or difficult operation and excessive free play.
5. Harness Connector (Instrument Panel wiring harness, Floor wiring harness)
Check harnesses for binding, connectors for damage, poor connection, and terminals for deform-
ation (refer to Instrument panel wiring harness/floor wiring harness section)
6. Seat Belt with Pre-Tensioner
6.1 Check the seat belt for damage or deformation.
6.2 Check the pre-tensioner for cracks or deformation.
6.3 Check that the unit is installed correctly to the vehicle body.
INDIVIDUAL COMPONENT SERVICE WCH52BICOMP11001
If the SRS componets and seat belt with pre-tensioner are to be removed or replaced as a result of
maintenance, troubleshooting, etc., follow each procedure (from page 52B/77 to page 52B/97 dis-
posal procedure).
CAUTION
(1) SRS componets and seat belt with pre-tensioner should not be subjected to heat, so remove the
2
SRS-ECU, air bag modules (driver's side and front passenger's side ), front seat assemblies (side
1 1
air bag module ), clock spring, side impact sensors , and seat belts with pre-tensioner before
drying or baking the vehicle after painting.
• SRS-ECU, air bag module, clock spring, side impact sensor1: 93°C or more.
• Seat belt with pre-tensioner: 90°C.
Recheck SRS system operability after re-installing them.
NOTE:
2: if so equipped

/ 74 WARNING / CAUTION LABEL
(2) If the SRS components and seat belts with pre-tensioner are removed for the purpose of check,
sheet metal repair, painting, etc., they should be stored in a clean, dry place until they are rein-
stalled.
WARNING / CAUTION LABEL WCH52BSASSY056
A number of caution labels relating to the SRS are found in the vehicle, as shown in the following il-
lustration. Follow label instructions when servicing SRS . The label for SRS component must not be
replaced.

WARNING / CAUTION LABEL / 75
DOIMC52BR07005
Symbol Description

/ 76 WARNING / CAUTION LABEL
A Clock spring
B Air bag module (Driver's side)
C Air bag module (Passenger's side if so equipped)
D SRS air bag control unit
E Warning label
F Sun visor
G Seatbelt pre-tensioner

SRS AIR BAG CONTROL UNIT (SRS-ECU) / 77
SRS AIR BAG CONTROL UNIT (SRS-ECU) WCH52BSASSY057
DOIMC52BR07006
CAUTION
(1) Disconnect the battery (-) terminal and wait for 5 minutes or more before starting work. The
disconnected battery terminal should be covered with tape to insulate it.
(2) Never attempt to disassemble or repair the Air Bag Control Unit. If faulty, replace it.
(3) Do not drop or subject the Air Bag Control Unit to impact or vibration.
If dents, cracks, or deformations are discovered on the Air Bag Control Unit, replace it.
(4) After deployment of an air bag, replace the Air Bag Control Unit with a new one.
(5) Never use an ohmmeter on or near the Air Bag Control Unit . Use the special tool specified at
52B/8 .
(6) Ensure that no surrounding part (example carpet, harness, hand brake cable, console box etc.)
touch / contact the Air Bag Control Unit. The minimum surrounding clearance for Air Bag Control
Unit must be 5 mm (0.2 in).
(7) Ensure that no rubber sealant or any part is between the Air Bag Control Unit and floor panel
during installation.

/ 78 SRS AIR BAG CONTROL UNIT (SRS-ECU)
• Turn the ignition key to the “LOCK” position
• Floor Console Removal (Refer to GROUP 52A — Floor Console)
Removal steps
• Post-installation inspection
1. Connector for the negative (-) battery cable to the battery.
2. Floor console assembly
3. Connector for the air bag control unit and the harness connector.
4. Earth harness
5. Air Bag Control Unit
T1 0.49 kgm (4.9 Nm, 3.54 ft.lbs) ± 0.098 kgm (0.98 Nm, 0.71 ft.lbs)

1. NEGATIVE (-) BATTERY CABLE FROM THE

CAUTION
After the ignition switch has been placed at the
LOCK position and the negative (-) terminal of
the battery has been disconnected, wait for at
least 5 min. before starting work. Wind a tape
around the disconnected (-) terminal for insula-
tion.
DOIMC015R07017 Symbol Description
A Positive (+) terminal
B Insulating tape negative (-) terminal
C Battery
3. DISCONNECTION FOR THE AIR BAG

CONTROL UNIT AND THE HARNESS BODY
CONNECTOR
• Press the stopper lock.
• Push the lock lever and remove outward the
harness side connector for disconnection.
Symbol Description
A Air bag control unit
B Stopper lock
C Lock lever
CAUTION
• Do not use excessive force to push the
lock lever and
be carefully not to exert undue force to
remove the connector as this will dam-
age them.
DOIHC52BR06004 INSPECTION
• Check the Air bag Control Unit case for dents
crack or deformities.
• Check connectors and lock lever for damage
and terminals for deformities.
CAUTION
If a dent, cracks and deformation replace the
SRS-ECU with a new one.
NOTE
For checking of the SRS-ECU other than described
above, refer to the section concerning
troubleshooting.

/ 80 SRS AIR BAG CONTROL UNIT (SRS-ECU)

5. AIR BAG CONTROL UNIT INSTALLATION
CAUTION
The SRS may not active if Air Bag Control unit
is not installed properly, which could result in
serious injury or death to the vehicle's driver or
front passenger in case of accident.
4. CONNECTION FOR THE EARTHING

HARNESS OF THE AIR BAG CONTROL UNIT
CAUTION
At the grounding point, ensure that the installa-
tion sequence of the Air Bag Control Unit include
the connection of the earthing harness. The SRS
will not function if Air Bag Control Unit is not
installed properly, which could result in serious
injury or death to the vehicle's driver or front
passenger in case of accident.
1. Fix the Air Bag Control Unit (C) to the floor
bolt hole.
2. Put the earthing harness (B) on the floor bolt
hole.
3. Tighten the bolts with earthing harness (B)
between bolt (A) and Air Bag Control Unit
(C).
Symbol Description
A Bolt
B Earthing harness
C Air Bag Control Unit
DOIMC52BR07007
3. CONNECTION FOR THE AIR BAG CONTROL

UNIT AND THE HARNESS SIDE CONNECTOR
1. Press the stopper lock.
2. Push inward the harness side connector and
push the lock lever to connect the harness
side connector securely.
Symbol Description
A Air Bag Control Unit
B Stopper lock
DOIHC52BR06006 C Lock lever

POST INSTALLATION INSPECTION

1. Reconnect the negative battery terminal.
Turn the ignition key to the “ON” position.
Does the SRS warning lamp illuminate for
about 4.5 seconds, and then extinguished
for at least 30 sec.
If yes. SRS system is functioning properly. If
no, consult page 52B/10 - Troubleshooting
INSPECTION
• Check the Air Bag Control Unit dents and
cracks or deformation.
DOIMC52BR07004 • Check connector for damage, and terminals
for deformation.
• Make sure no surrounding part (example
carpet, harness, handbrake cables, console
box etc.) touching / in contact with Air Bag
Control Unit. The surrounding clearance for
SRS-ECU must be minimum 5 mm (0.2 in)
around.
• Make sure no rubber sealant or any part
between the SRS-ECU and floor consule in-
stallation.
CAUTION
If a dent, crack and deformation replace the Air
Bag Control unit with a new one.

/ 82 AIR BAG MODULE AND CLOCK SPRING
AIR BAG MODULE AND CLOCK SPRING WCH52BSASSY058
DOIMC52BR07003

AIR BAG MODULE AND CLOCK SPRING / 83
CAUTION
(1) Disconnect the battery (-) terminal and wait for 5 minutes or more before starting work. The
disconnected battery terminal should be covered with tape to insulate it.
(2) Never attempt to disassemble or repair the air bag module or clock spring.
If faulty, replace it.
(3) Do not drop the air bag module or clock spring or allow contact with water, grease or oil.
Replace it if a dent, or crack deformation are detected.
(4) The air bag module should be stored and placed on a flat surface so that the pad surface is facing
upward.
Do not place anything on top of it.
(5) Do not expose the air bag module to temperature over 85 °C (185 °F).
(6) When the driver's side and front passenger's side air bags(1) have been deployed, the air bag
(2)
modules (driver's side and front passenger's side ) should be replaced with new modules. When
(3)
a side air bag has been deployed, the front seat back assembly (driver's seat or passenger's
seat) should be replaced with a new assembly.
(7) After deployment of an air bag, replace the clock spring with a new one.
(8) Wear gloves and safety glasses when handling an air bag that has already deployed.
• After setting the steering wheel and the front wheels to the straight ahead position, remove the
ignition key.
Clock Spring removal steps
• Pre-installation inspection (Refer to Installation of Steering GROUP 37A-STEERING)
1. Connector for the negative (-) battery cable to the battery
2. Air bag module
3. Steering wheel
4. Clock spring and body wiring harness connection
5. Column switch
• Pre-installation inspection
Air Bag Module removal steps
1. Connector for the negative (-) battery cable to the battery
2. Air bag module
T1 3.3 - 4.9 kgm (33 - 49 Nm, 23.87 - 35.44 ft.lbs)
T2 0.7 - 1.1 kgm (7 - 11 Nm, 5.06 - 7.96 ft.lbs)
T3 0.069 kgm (0.69 Nm, 0.5 ft.lbs) ± 0.015 kgm (0.15 Nm, 0.11 ft.lbs)
NOTE:
(1) if so equipped
(2) if so equipped
(3) if so equipped

1. NEGATIVE (-) BATTERY CABLE FROM THE

tape the terminal.
CAUTION
work.
DOIMC015R07017
Symbol Description
A Battery cable
B Insulating tape
C Battery
DRIVER FRONT AIR BAG MODULE REMOVAL

1. Untighten the air bag module mounting
screws (torque screws) at the side of the
steering wheel.
NOTE
Do not remove the screws from the holders.
Symbol Description
1 Wheel steering
2 Mounting screw
DOIJC52BR04079 3 Torque screw
2. When disconnecting the connector of the
clock spring from the air bag module, press
the air bag's lock towards the outer side to
spread it open. Use a flat-tipped screwdriver,
as shown in the figure at the left, to pry so
as to remove the connector gently.
CAUTION
(1) When disconnecting the air bag module
clock spring connector, take care not to
apply excessive force to it.
(2) The removed air bag module should be
stored in clean, dry place with the pad
DOIJC52BR04080
cover face up.
Symbol Description
1 Lock
2 Flat-tapped screwdriver
CLOCK SPRING REMOVAL

CAUTION
The removed clock spring should be stored in a
clean, dry place clock spring face up.

INSPECTION
CLOCK SPRING
Disconnect body harness from clock spring
socket.
PRE-INSTALLATION INSPECTION
1. When installing the new air bag module and
clock spring, refer to INSPECTION section
(refer on next page).
DOIMC52BR07004
2. Connect the battery (-) terminal and turn the

ignition on.
Symbol Description
A Battery cable
B Insulating tape
C Battery
3. Turn the ignition switch to on position and
observe the characteristic of SRS warning
lamp
4. Ensure entire SRS operates properly except
DOIMC015R07017
open circuit of air bag module.
5. Turn the ignition key to the “LOCK” position,
disconnect the negative battery cable and
tape the terminal.
CAUTION
work.
INSPECTION
AIR BAG MODULE
1. If any improper part is found during the fol-
lowing inspection, replace the air bag mod-
ule with a new one. All airbags removed
from vehicle must be shipped to designated
handled by unauthorized personal.
CAUTION
ance of the air bag module (Squib) even if
DOIJC52BR04013
cuit resistance is measure with a tester, acci-

dental air bag deployment will result in ser-

ious personal injury.
Symbol Description
A Pad cover
1. Check pad cover for dents, cracks or deform-
ities.
3. Check hooks and connector for damage,
binds.
deformities.
5. Install the air bag module to steering wheel
to check fit or alignment with the wheel.
CLOCK SPRING
1. If as result of following checks, even one
abnormal point is discovered, replace the
clock spring with a new one.
1.1 Check connectors and cable for damage,
terminal for deformities or no continu-
ity.
1.2 Visually check the housing damage.
Symbol Description
A Window
B Mating marks
DOIMC52BR07013
C Harness horn
D Harness SRS
CLOCK SPRING CHECK
If, as result of the following checks, even one
abnormal point is discovered, replace the clock
spring with a new one.
1. Check connectors and flat cable for damage
terminals deformation or discontinuity.
2. Visually check the case for damage.
3. Check that there is continuity between con-
nector No. 2 and terminal No. 4 of connector
No.1 of the clock spring.


5. CLOCK SPRING INSTALLATION
1. Make sure front wheels are in straight posi-
tion.
Symbol Description
A Window
B Mating marks
C Harness horn
D Harness SRS
DOIMC52BR07013
2. Turn the clock spring to clock wise fully, and
then turn it back to approx. 3 1/8 turns
counter clockwise to align the mating mark.
Make sure that all connector are at 6 o'clock
(Neutral) position.
CAUTION
If the clock spring's mating mark is not properly
aligned, the steering wheel may not be com-
pletely rotational during a turn, or the flat cable
within the clock spring may be damaged or there
is no continuity resulting in obstructing normal
operation of the SRS and possibly leading to
serious injury to the vehicle's driver.
(1) During installation of the steering wheel or
clock spring, ensure that the flat cable of the
clock spring does not become caught,
tangled or in tension condition.
(2) Be sure the cable ties are used to tie the
connector of clock spring to steering column
assy.
(3) The clock spring flat cable or terminal can
be damaged due to improper cable routine
and installation.
3. STEERING WHEEL INSTALLATION

1. Before installing the steering wheel, be sure
to first turn the vehicle's front wheels to the
straight-ahead position and align the mating
mark and “NEUTRAL” accordingly to the in-
stallation service point for clock spring.
CAUTION
(1) During installation of the steering wheel,
ensure that the cable of the clock spring
does not become caught or tangled.
(2) The clock spring flat cable or terminal
can be damaged due to improper cable
routine and installation.
2. After clamping, turn the steering wheel all
the way in both directions to confirm that
steering is normal.

2. DRIVER FRONT AIR BAG MODULE

INSTALLATION
1. Connect the air bag module connector se-
curely.
2. Place the air bag module assembly in position
and re-tighten torque bolt from rear side.
Standard Value:
Tightening torque 0.7 kgm (7 Nm, 5.06 ft.lbs)
~1.1 kgm (11 Nm, 7.96 ft.lbs)
CAUTION
Never connect battery or switch ignition ON
while installing the air bag module.
2. POST-INSTALLATION INSPECTION
1. After installing the clock spring, the steering
wheel, the column cover and the air bag
module, check steering wheel for noise, binds
or operation difficulty. Turn the steering
wheel right and left lightly to see its smooth
operation, and free from abnormal noise.
2. Reconnect the negative battery terminal.
Turn the ignition key to the “ON” position.
3. Ensure that the “SRS” warning lamp illumin-
ate for about 3 seconds, and then remain
DOIMC52BR07004 extinguished for at least 30 seconds. If this
condition does not meet, consult page
52B/10 .

INSPECTION
DRIVER AIR BAG MODULE / FRONT PASSENGER
3
AIR BAG MODULE CHECK
ule with a new one. Dispose the old accord-
ing to the specified procedure.
CAUTION
ance of the air bag modules (squib) even if
accidental air bags deployment will result in
3. Check connectors for damage, terminals for
deformation, and harness for binds.
4. Check air bag inflator case for dents, cracks
or deformation.
5. Install the driver front air bag module to
steering wheel to check fit or alignment with
the wheel.
CAUTION
DOIJC52BR01019
If dents, cracks, deformation are discovered
in the air bag module, replace it with a new
one. Dispose the old one according to the
specified procedure.
NOTE:
3: if so equipped

/ 90 FRONT PASSENGER AIR BAG MODULE
FRONT PASSENGER AIR BAG MODULE WCH52BSASSY077
DOIMC52BR10021
Front passenger's air bag module removal steps

• Pre-installation inspection (Refer to Installation of Instrument Panel Assembly MODULE 1.10 —
GROUP 52A)
1. Connection for the negative (-) battery cable to the battery
2. Instrument panel
3. Front passenger's air bag module
• Pre- installation inspection
T1 0.6 kgm (6 Nm, 4.34 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
T2 1.6 kgm (16 Nm, 11.57 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)

FRONT PASSENGER AIR BAG MODULE / 91
1. NEGATIVE (-) BATTERY TERMINAL FROM

THE BATTERY DISCONNECTION
1. Disconnect the negative (-) battery terminal
and tape the terminal.
CAUTION
the battery terminal before doing any fur-
ther work.
DOIMC015R07017
Symbol Description
A Positive (+) battery terminal
B Negative (-) battery terminal
covered with insulating tape
C Battery
REMOVAL OF THE FRONT PASSENGER'S AIR

BAG MODULE
1. The bolts of front passenger's air bag module
can only be removed from bottom side of
the instrument panel. The location of those
bolts to be removed are shown in the illustra-
tion.
DOIMC52BR10033
2. Untighten the nuts of the front passenger's

air bag module at the side of the air bag
module (Location of nuts are shown in the
illustration).
DOIMC52BR10039

/ 92 FRONT PASSENGER AIR BAG MODULE
3. Open the front passenger's air bag from up-

per side of the instrument panel by using a
stick to prevent instrument panel from dents,
cracks or deformities (as shown in the figure).
CAUTION
(1) When disconnecting the air bag module
clock spring connector, be careful not to
apply excessive force to it. DO NOT for-
get to unlock the lock lever in the first
place.
(2) Be careful when handling the removed
front passenger's air bag. Ensure to use
DOIMC52BR10023
one hand to hold the top cover and
other hand to hold the inflater case. This
is to prevent the air bag module from
dropping which may cause injury to the
carrier.
(3) The removed air bag module should be
stored in clean, dry place with the pad
cover face up.
4. When disconnecting the dash harness con-
nector (B) from the front passenger's air bag
module, push the lock lever (A) outward to
spread it open by using a flat-tip screwdriver
(C) (as shown in the figure).
Symbol Description
A Lock lever
B Harness connector
C Flat-tip screwdriver
DOIMC52BR10040
5. Disconnect the harness connector completely

from the front passenger's air bag module
gently.
1. When installing the front passenger air bag
module, refer to INSPECTION section.
1. PASSENGER FRONT AIR BAG MODULE

INSTALLATION
DOIMC52BR10032
1. Connect the air bag module connector se-
curely.
2. Place the air bag module assembly in position
and re-tighten torque bolt from rear side.
Standard Value:
Tightening torque 0.5 kgm (5 Nm, 3.62 ft.lbs)
~0.7 kgm (7 Nm, 5.06 ft.lbs)

FRONT PASSENGER AIR BAG MODULE / 93
CAUTION
DO NOT connect battery while connecting
or disconnecting the air bag module.
DO NOT switch the ignition key to “ON”
position while connecting or disconnecting
the air bag module.
POST-INSTALLATION INSPECTION
1. After installing the clock spring, the steering
wheel, the column cover and the air bag
module, check steering wheel for noise, binds
or operation difficulty. Turn the steering
wheel right and left lightly to see its smooth
operation, and free from abnormal noise.
2. Reconnect the negative (-) battery terminal.
Switch the ignition key to “ON” position.
3. Ensure that the “SRS” warning lamp blinks
DOIMC52BR10041 6 times, and then turn off permenantly? If
this condition does not meet. Refer to SRS
WARNING LAMP INSPECTION 52B/10 .
INSPECTION
FRONT PASSENGER'S AIR BAG MODULE
ule with a new one. All airbags removed
from vehicle must be shipped to designated
handled by unauthorized personal.
CAUTION
ance of the air bag modules (squib) even if
DOINC52BR09038
accidental air bags deployment will result in
3. Check connectors for damages, terminals for
deformities, and harness for binds.
4. Check air bag inflator case for dents, cracks
or deformities.
5. Install the front passenger air bag module
to instrument panel to check the fitting.
CAUTION
If dents, cracks or deformities are discovered
in the air bag module, replace it with a new
one.
Symbol Description
B Front passenger's airbag mod-
ule

/ 94 AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURE
AIR BAG MODULE AND SEAT BELT

PRE-TENSIONER DISPOSAL
PROCEDURE WCH52BDSPOS001
GENERAL INFORMATION
Before disposing of a vehicle which is equipped
with air bags or seat belts with pre-tensioner, or
when disposing of the air bags or seat belt pre-
tensioner themselves, the following procedures
must be used to deploy the air bags or operate
the seat belt pre-tensioners before disposal.
WARNING
Disposal procedure should be handled or per-
formed by an authorised personal.Please consult
your local dealer.
CAUTION
(1) If the vehicle is to be scrapped or otherwise
disposed of, deploy the air bags and operate
the seat belt pre-tensioners inside the
vehicle. If the vehicle will continue to be
operated and only the air bag modules and
seat belt pre-tensioner are to be disposed
of, deploy the air bags and operate the seat
belt pre-tensioners outside the vehicle.
(2) Since a large amount of smoke is produced
when air bag is deployed or the seat belt
pre-tensioner is operated, avoid residential
areas whenever possible.
(3) Since there is a loud noise when the air bags
are deployed and when the seat belt pre-
tensioners are operated, avoid residential
areas whenever possible. If anyone is
nearby, give warning of the impending
noise.
(4) Suitable ear protection should be worn by
personnel performing these procedures or
by people in the immediate area.

SEAT BELT WITH PRETENSIONER / 95
SEAT BELT WITH PRETENSIONER WCH52BSASSY059
DOIMC52BR07008

/ 96 SEAT BELT WITH PRETENSIONER
CAUTION
(1) Disconnect the battery (-) terminal and wait for 5 min. or more before starting work. Furthermore,
the disconnected battery terminal should be covered with tape to insulate it.
(2) Never attempt to disassemble or repair the seat belt with pre-tensioner. Do not subject it to
shocks, drop it, bring it close to strong magnets or allow contact with water, grease or oil. Always
replace it with a new part if any dents, cracks or deformation is found.
(3) Do not place anything on top of the seat belt pre-tensioner.
(4) Do not expose the seat belt with pre-tensioner to temperatures over 85 °C (185 °F).
(5) After operating the seat belt pre-tensioner, replace the seat belt pre-tensioner with a new part.
(6) Wear gloves and safety glasses when handling an air bag that has already deployed.
(7) If disposing of a seat belt with pre-tensioner which has not yet been used, its pretensioner
should be operated first before disposal.
• Turn the ignition key to the “LOCK” position
• Center pillar lower trim removal and installation (Refer to GROUP 52A — Center pillar lower
trim).
Removal steps
• Negative (-) battery cable connection
1. Disconnect the battery (-) terminal
2. Sash guide cover
3. Seat belt with pre-tensioner
4. Disconnect pre-tensioner connector
NOTE :
After provisionally tightening the seat belt assembly mounting bolt in every installation location,
fully tighten them to the specified torque.
T1: 3.0 - 4.5 Kgf.m

UN-DEPLOYED AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL / 97

WCH52BSPROC11005
1. When installing a new seat belt with pre-
tensioner refer to “INSPECTION”
CAUTION
Disposal of the pre-tensioner must be carried
out as stated in the procedure.
2. Connect the battery (-) terminal
3. Turn the ignition switch to “ON” position.
4. Ensure that the “SRS” warning lamp illumin-
DOIMC52BR07004
ate for about 3 seconds, and then remain
extinguished for at least 30 seconds. If this
condition does not meet, consult page
52B/10 .
INSPECTION
SEAT BELT WITH PRE-TENSIONER CHECK
If any part is found to be faulty during the in-
spection, it must be replaced with a new one.
CAUTION
of the seat belt pre-tensioner even if you are
using the specified tester. If the circuit resistance
is measured with a tester, the seat belt pre-ten-
sioner may accidentally operate, which could
result in serious personal injury.
1. Check seat belt pre-tensioner for dents,
cracks or deformation.
2. Check connectors for damage, and terminals
for deformation, and harness for binds.
UN-DEPLOYED AIR BAG MODULE

AND SEAT BELT PRE-TENSIONER
DISPOSAL WCH52BDSPOS11001
CAUTION
Before disposing vehicle equipped with airbag
or seat belt with pre-tensioner, or when dispos-
ing of the airbags or seat belt pre-tensioner
themselves,the following procedures must be
used to deploy the airbag or operate the seat
belts pre-tensioner before disposal.
WARNING
Disposal procedure should be handled or per-
formed by an authorised personal.Please consult
your local dealer.
DEPLOYMENT INSIDE THE VEHICLE
1. Move the vehicle to an isolated spot.

/ 98 UN-DEPLOYED AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL
2. Disconnect the negative (-) and positive (+)

battery cables from thr battery terminals,
and then remove the battery from the
vehicle.
CAUTION
Wait at least 60 seconds after disconnecting
the battery cables before doing any further
work (refer to 52B/5 — SRS Service Precau-
tion)
3. Deploy each air bag module and seat belt
pre-tensioner in the following procedures
Driver's air bag module

1. Remove the steering column cover lower.
2. Remove the connection between the clock
spring connector (red) and the instrument
panel wiring harness connector.
DOIMC52BR07038
NOTE
If the clock spring connector is disconnected
from the instrument panel wiring harness,
both electrodes of the clock spring connector
will be automatically shorted to prevent un-
intended deployment of the driver's air bag
due to static electricity, etc.
3. Connect two wires, each six metres or longer,
to the two leads of SRS air bag adapter har-
ness and cover the connections with insula-
tion tape. The other ends of the two wires
should be connected to each other (short-
DOIMC52BR07016 circuited), to prevent sudden unexpected
deployment of the driver's air bag.
Symbol Description
A SRS air bag adapter harness
B Insulation tape
C Connection
D Deployment wires

4. Connect the SRS air bag adapter harness to

the clock spring connector and pull the de-
ployment wires out of the vehicle.
Symbol Description
A Clock spring connector
B SRS air bag adapter harness
C Deployment wires
DOIMC52BR07017
5. Fully close all door windows, close the doors

and place a cover over the vehicle to minim-
ize the amount of noise.
Symbol Description
A Cover
B Deployment wires
CAUTION
If the glass is damaged, it may break, so the
car must be covered.
6. Disconnect the deployment wires as far from
DOIMC52BR07018 the vehicle as possible and connect the wires
to the terminals of the battery removed from
the vehicle. Deploy the driver's air bag mod-
ule.
CAUTION
• Before deploying the air bag in this man-
ner, first check to be sure that there is no
one in or near the vehicle. Wear safety
glasses.
• The deployment of the driver's air bag
makes the inflator very hot. Before handling
the insulator, wait more than 30 minutes for
cooling.
• If the air bag module fails to deploy when
the procedures above are followed, do not
go near the module. Contact your local dis-
tributor.
7. After deployment, dispose of air bag module
according to the Deployed Air bag Module
and Seat Belt Pre-Tensioner Disposal Proced-
ures section.

Seat belt pre-tensioner

1. Remove the center pillar lower trim (refer to
GROUP 52A — Center pillar lower trim)
Symbol Description
Seat belt pre-tensioner con-
A
nector
B SRS ECU connector
2. <For Driver's Side> Remove the connection
between the seat belt pre-tensioner and the
SRS-ECU connector.
DOIMC52BR07019 NOTE
If the seat belt pre-tensioner connector is
disconnected from the SRS-ECU, both elec-
trodes of the seat belt pre-tensioner connect-
or will be automatically shorted to prevent
unintended deployment of the seat belt pre-
tensioner due to static electricity, etc.
3. Connect two wire, each six meters or longer,
to the two leads of SRS air bag adpater har-
should be connected to each other (short
circuited), to prevent sudden unexpected
deployment of the seat belt pre-tensioner.
Symbol Description
B Insulation tape
C Connection
DOIMC52BR07016
D Deployment wires
4. Connect the seat belt connector to SRS air
bag adapter harness and pass the deploy-
ment wires out of the vehicle
Symbol Description
B Seat belt pre-tensioner
C Deployment wires
DOIMC52BR07020

5. Fully close all door windows, close the doors

and place a cover over the vehicle to minim-
ize the amount of noise.
Symbol Description
A Cover
B Deployment wires
CAUTION
If the glass is damaged, it may break so the
car must be covered.
DOIMC52BR07018 the vehicle as possible and connect the wires
to the terminals of the battery removed from
the vehicle. Deploy the seat belt pre-tension-
er.
CAUTION
• Before deploying the seat belt pre-tension-
er in this manner, first check to be sure that
there is no one in or near the vehicle. Wear
safety glasses.
• The deployment of the seat belt pre-ten-
sioner makes the inflator very hot. Before
handling the inflator, wait more than 30
minutes for cooling.
• If the seat belt pre-tensioner fails to deploy
when the procedures above are followed,
do not go near the seat belt pre-tensioner.
Contact your local distributor.
7. After deployment, dispose of seat belt pre-
tensioner according to the Deployed Air Bag
Module and Seat Belt Pre-Tensioner Disposal
Procedures (refer to 52B/105 )
DEPLOYMENT OUTSIDE THE VEHICLE
CAUTION
• This should be carried out in a wide, flat area
at least 6m away from obstacles and other
people.
• Do not deploy outside if the weather is wind-
ing. Even in a soft wind, ignite to windward of
the air bag modules or seat belt pre-tensioner.
1. Disconnect the negative (-) and positive (+)
batttery cables from the battery terminal,
and remove the battery from the vehicle.
CAUTION
Wait at least 60 seconds after disconnecting
the battery cables before doing any further
work (refer to 52B/5 )
2. Deploy each air bag module, seat belt pre-
tensioner in the following procedures.

Driver's side air bag module

1. Remove the driver's side air bag module from
the vehicle (refer to 52B/82 — SRS Service
Precaution)
CAUTION
The driver's side air bag module should be
stored on a flat surface and placed so that
the air bag deployment surfaces are facing
upward. Do not place anything on top of
them.
2. Connect two wires, each six meters or longer,
deployment of the driver's side air bag.
Symbol Description
B Deployment wires
C Connection
DOIMC52BR07022
D Insulation tape
3. Install a nut to the bolt behind the driver's
side air bag module and tie thick wire for
securing to the wheel.
4. Take the SRS air bag adapter harness that is
connected to the wires, pass it beneath the
old tyre wheel assembly, and connect it to
the driver's side air bag module.
Symbol Description
A Deployment wires
B Driver's side air bag module
5. With the driver's side air bag module up-
wards, place it in the wheel of old tyre and
secure with the wire tied to the bolt.
DOIMC52BR07023 CAUTION
Slack the deployment wires below the
wheel. If deployment wires are tight, the
reaction when the air bag deploys could
damage the adaptor harness.

6. Place three old tyres without wheels on top

of the tyre secured to the driver's side air bag
module.
Symbol Description
A Tyres without wheels
B Deployment wires
DOIMC52BR07024

the driver's side air bag module as possible
and connect the wires to the terminals of the
battery removed from the vehicle. Then de-
ploy
Symbol Description
A Deployment wires
CAUTION
• Before the deployment, be seure that no
one is near the driver's side air bag module.
• The deployment of the driver's side air bag
DOIMC52BR07025
makes the inflator very hot. Before handling
the inflator, wait more than 30 minutes for
cooling.
• If the driver's side air bag module fails to
deploy when the procedures above are fol-
lowed, do not go near the module. Contact
your local distributor.
8. After deployment, dispose of air bag module
according to the Deployed Air Bag Module
and Seat Belt Pre-Tensioner Disposal Proced-
ures (refer to 52B/105 )
Seat belt pre-tensioner
1. Remove the seat belt pre-tensioner from the
vehicle (refer to 52B/95 )
CAUTION
The seat belt pre-tensioner should be stored
on a flat surface and placed so that the air
bag deployment surfaces are facing upward.
Do not place anything on top of them.

2. Connect two wires, each six meters or longer,

deployment of the seat belt pre-tensioner.
Symbol Description
B Insulation tape
C Connection
DOIMC52BR07016
D Deployment wires
3. Take the SRS air bag adapter harness that is
connected to the wires, pass it beneath the
old tyre wheel assembly, and connect it to
the seat belt pre-tensioner.
Symbol Description
A Seat belt pre-tensioner
B Deployment wires
4. Pass the wires through the hole on the seat
belt retractor bracket and secure them to the
front (raised part) of the wheel on two
places.
DOIMC52BR07027
CAUTION
• Slack the deployment wires below the
wheel. If deployment wires are tight, the
reaction when the seat belt pre-tensioner
deploys could damage the adaptor harness.
• The connector of the SRS air bag adapter
harness should be placed so that it is not
clamped by the tyres during deployment or
operation.
• Pull the seat belt out the outside of the
tyre, and then place one tyre without a
wheel on top of the existing tyre.
DOIMC52BR07028

DEPLOYED AIR BAG MODULE OR OPERATED SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES / 105
5. Place the three old tyres without wheels on

top of the tyre secured to the seat belt pre-
tensioner.
Symbol Description
A Tyres without wheels
B Deployment wires
DOIMC52BR07024

the seat belt pre-tensioner as possible and
connect the wires to the terminals of the
battery removed from the vehicle, and de-
ploy
Symbol Description
A Deployment wires
CAUTION
• Before the deployment, be sure that no
one is near the seat belt pre-tensioner.
• The deployment of the seat belt pre-ten-
DOIMC52BR07025
sioner make itself very hot. Before handling
the seat belt pre-tensioner, wait more than
30 minutes for cooling.
• If the seat belt pre-tensioner fails to deploy
when the procedures above are followed,
do not go near the seat belt pre-tensioner.
Contact your local distributor.
7. After deployment, dispose of set belt pre-
tensioner according to the Deployed Air Bag
Module and Seat Belt Pre-Tensioner Disposal
Procedures (refer to 52B/105 )
DEPLOYED AIR BAG MODULE OR

OPERATED SEAT BELT
PRE-TENSIONER DISPOSAL
PROCEDURES WCH52BDSPOS003
After deployment or operation, the air bag

module and the seat belt pre-tensioner should
be disposed of in the same manner as any other
scrap parts, adhering to local laws and/or legisla-
tion that may be in force except that the follow-
ing points should be carefully noted during dis-
posal
1. The inflator will be quite hot immediately
following deployment, so wait at least 30

/ 106 DEPLOYED AIR BAG MODULE OR OPERATED SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES
minutes to allow it cool before attempting

to handle it.
2. Do not put water or oil on the air bag after
deployment or on the seat belt pre-tensioner
after operation.
3. There may be, adhered to the deployed air
bag module or the operated seat belt pre-
tensioner, material that could irritate the eye
and/or skin, so wear gloves and safety glasses
when handling a deployed air bag module
or operated seat belt pre-tensioner.
CAUTION
If after following these pre-cautions, any
material does get into the eyes or on the
skin, immediately rinse the affected area
with a large amount of clean water. If any
irritation develope, seek medical attention.
4. Tightly seal the air bag module and seat belt
pre-tensioner in a strong vinyl bag for dispos-
al
Symbol Description
Air bag module and seat
A
belt pre-tensioner
B Strong vinyl bag
5. Be sure to always wash your hands after
completeing this operation.
DOIMC52BR07015

CHASSIS ELECTRICAL 54
Content /1
54 CHASSIS ELECTRICAL
COMBINATION METER ............................................................... 54/2
SERVICE SPECIFICATIONS .......................................................... 54/2
SEALANT ............................................................................. 54/2

/2 COMBINATION METER
COMBINATION METER WCH054SPECS11001
SERVICE SPECIFICATIONS
Temperature level:
Indication bar Temperature level display
130 °C (266 °F) 6 BAR
120 °C (248 °F) 5 BAR
110 °C (230 °F) 4 BAR
75-105 °C (167-221 °F) 3 BAR
70 °C (158 °F) 2 BAR
50 °C (122 °F) 1 BAR
Fuel level:
Indication bar Temperature level display
Full 6 BAR
3/4 5 BAR
2/4 4 BAR
1/4 3 BAR
Warning 2 BAR
Empty 1 BAR
Fuel gauge:
Items Standard value
Fuel gauge unit resistance Float point F 26 Ω 5Ω
Ω –5Ω
Float point E 285 Ω ± 5 Ω
Fuel gauge unit float height A (Float point F) 167 mm (6.57 in) ± 2 mm (0.079 in)
B (Float point E) 20 mm (0.79 in) ± 2 mm (0.079 in)
Speedometer indication tolerance:
Nominal speed (km/h) 20 40 60 80 100 120 140 160 180 200
Tolerance (km/h) +4.0 +4.0 +5.5 +7.5 +9.5 +11.5
— — — —
0 0 +0.5 +1.5 +2.5 +3
Tachometer indication tolerance:
Nominal (rpm) 1000 2000 3000 4000 5000 6000 7000 8000 9000
Tolerance (rpm) +100 +100 +100 +100 +100 +100 +100 +100 +100
–100 –100 –100 –100 –100 –100 –100 –100 –100
SEALANT
Items Specified sealant Remark
Engine coolant temperature 3M Adhesive nut locking No. 4171 or Drying
gauge unit threaded portion equivalent

CHASSIS ELECTRICAL 54
COMBINATION METER /3
FUEL GAUGE HARNESS INSPECTION

WCH054SPROC11002
HARNESS SIDE:
Symbol Description
A Test lamp 12V-3.4W
1 Fuel gauge (Meter)
2 Fuel pump (+)
3 —
4 Fuel pump (-)
5 Fuel gauge (Ground)
DOIMC054R11010
State Number State Condition Next state

1 Remove the fuel gauge go to state 2
—
unit connector
2 Key at start or ignition Test lamp illuminate Replace the pump
position. Use the special Test lamp not illuminate Repair the harness
tool to connect a test
lamp12 V) to the harness
connector (Pin no. 2 and
no. 4).
3 When the ignition switch Test lamp illuminate Replace the fuel gauge
is turned to “ON” posi- unit
tion. Use the special tool Test lamp not illuminate Repair the harness
to connect a test lamp12
V) to the harness connect-
or (Pin no. 1 and no. 5).
FUEL GAUGE UNIT INSPECTION
To check, remove the fuel gauge unit from the
fuel tank. (Refer to GROUP 13 – fuel tank.)
Fuel gauge unit resistance :
1. Check that resistance value between the fuel
gauge terminal and earth terminal is at
standard value when fuel gauge unit float
is at point F (highest) and point E (lowest).
Standard value:
Point F +5Ω
(highest) 26 Ω
–5Ω
Point E +5Ω
(lowest) 285 Ω
–5Ω

/4 COMBINATION METER
2. Check that resistance value changes smoothly

when float moves slowly between point F
(highest) point E (lowest).
Symbol Description
1 Fuel gauge (Meter)
2 Fuel pump (+)
3 —
4 Fuel pump (–)
5 Fuel gauge (Ground)
DOIMC054R11011
Fuel gauge unit float height :

Move float and measure the height A at point F
(highest) and B at point E (lowest) with float arm
touching stopper.
Symbol Description
C Point F (highest)
D Point E (lowest)
Standard value:
A : 167 mm (6.57 in) ± 2 mm (0.079 in)
B : 20 mm (0.79 in) ± 2 mm (0.079 in)
DOIMC054R11009

HEATER, AIR CONDITIONER AND VENTILATION 55
Content /1
55 HEATER, AIR CONDITIONER AND VENTILATION

SPECIFICATIONS ....................................................................... 55/2
REFRIGERANT LINE ................................................................... 55/3

COMPRESSOR .......................................................................... 55/7


/2 SPECIFICATIONS
R-134a, Approx.
Refrigerant and quantity SANDEN / APM
450 g (15.88 oz, 4.5 N) ± 50 g (1.76 oz, 0.5 N)

REFRIGERANT LINE /3
REFRIGERANT LINE WCH055SASSY11001
DOIMC055R11002

/4 REFRIGERANT LINE

• Discharging and charging of Refrigerant (Refer to page GROUP 055).
• Front Bumper removal and installation (Refer to GROUP 51 EXTERIOR).
• Master cylinder and brake booster (Refer to GROUP 35B SERVICE BRAKE).
Compressor oil: SANDEN SP 10

Removal steps
1. Hose suction
2. Oil ring
3. Pipe suction
4. Oil ring
5. Hose, discharge
6. Oil ring
7. Pipe liquid A
8. Oil ring
9. Pipe liquid B
10. Compressor assy
T1 :0.4- 0.6 kgm (4- 6 Nm, 2.89- 4.34 ft.lbs)
T2 :1.2 - 1.4 kgm (12 - 14 Nm, 8.68 - 10.13 ft.lbs)
T3 :1.2 - 1.5 kgm (12 - 15 Nm, 8.68 - 10.85 ft.lbs)
T4 :3.0 - 3.5 kgm (30 - 35 Nm, 21.7 - 25.32 ft.lbs)

REFRIGERANT LINE /5
PIPE LIQUID B / PIPE SUCTION DISCONNEC-

TION
1. Drain brake oil reservoir.
2. Disconnect brake oil reservoir from brake
booster pump.
3. Disconnect the brake pipeline (right).
Symbol Description
A Brake oil reservoir
B Brake pipeline
DOIMC055R08415
4. Disconnect pipe liquid A from pipe liquid B.

5. Disconnect hose suction from pipe suction.
DOIMC055R08416
6. Disconnect both pipe suction and pipe liquid

B from evaporator.
Symbol Description
1 Pipe suction
2 Pipe liquid B
7. Remove both pipe suction and pipe liquid B.
If required, the hose suction can be removed
by disconnecting the other end that attached
to the compressor.
CAUTION
DOIMC055R08417 Plug or seal the disconnected pipelines and hoses
completely in order not to let foreign materials
(e.g. water vapour) get into them.
PIPE LIQUID B / PIPE SUCTION INSTALLATION
Installation of pipe liquid B / pipe suction can be
done by reversing the removal process. When
replacing the hose suction, refill it with a spe-
cified amount of compressor oil, and then install
them.
Use compressor oil to lubricate all oil ring.

/6 REFRIGERANT LINE
Compressor oil:
SANDEN SP 10
Items Quantity
Suction hose 30 cm³ (1.83 cu.in)

COMPRESSOR /7
COMPRESSOR WCH055SASSY11002
DOIMC055R11001

/8 COMPRESSOR
Pre-Removal Operation
• Discharging of Refrigerant (Refer to page Group 055.)
Post-Installation Operation
• FEAD Belt Tension Adjustment (Refer to page Group 11A Engine- FEAD Belt.)
• Charging of Refrigerant (Refer to page Group 055.)
Compressor oil: SANDEN SP10.

PC — Piping connection
Non-reusable part
Removal steps
1. Drive tensioner assy
2. FEAD belt
3. Suction hose connection
4. Discharge hose connection
5. O-ring
6. Compressor
T1 :2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T2 :4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)
T3 :2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T4 :4.2 - 4.4 kgm (42 - 44 Nm, 30.38 - 31.83 ft.lbs)

BULLETIN ALL
Index /1
ABS-ECU...................................................... 35B/38
Diagnosis Code............................................. 35B/8

SAGA Model YR 2011 English Edition RDCE-08MA010-05 August 2011 Printed in Malaysia

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BULLETIN

00 OUTLINE OF CHANGES ............................................................... 00/1 - 00/14

Printed in Malaysia 24 August 2011 Eng

Printed in Malaysia 24 August 2011 Eng

VEHICLE IDENTIFICATION ............................................................ 00/10

MAJOR SPECIFICATIONS ............................................................. 00/13

Printed in Malaysia 24 August 2011 Eng

OUTLINE OF CHANGES WCH000OLINE11003

WORKSHOP MANUAL PUBLICATION NUMBER

Printed in Malaysia 24 August 2011 Eng

RDWE- RDWE- RDWE- RDWE-

Printed in Malaysia 24 August 2011 Eng

RDWE- RDWE- RDWE- RDWE-

• CYLINDER HEAD GASKET

GRP 13A – FUEL • Update for new troubleshooting

Printed in Malaysia 24 August 2011 Eng

Change Items Reference Page Description Of Changes

• INTAKE MANIFOLD AND VACUUM

GRP 21– CLUTCH

Printed in Malaysia 24 August 2011 Eng

Change Items Reference Page Description Of Changes

GRP 23– CVT

Printed in Malaysia 24 August 2011 Eng

Change Items Reference Page Description Of Changes

• CVT FLUID COOLER

• Update information for drive

— Installation service point

• TRANSMISSION MOUNTING • Update information for transmis-

Printed in Malaysia 24 August 2011 Eng

Change Items Reference Page Description Of Changes

Printed in Malaysia 24 August 2011 Eng

Change Items Reference Page Description Of Changes

• WARNING / CAUTION LABEL

Printed in Malaysia 24 August 2011 Eng

Change Items Reference Page Description Of Changes

• SEAT BELT WITH PRETENSIONER

GRP 55– HEATER, AIR CONDITIONER

VEHICLE IDENTIFICATION WCH000VIDEN11003

Printed in Malaysia 24 August 2011 Eng

No. Items Contents

Printed in Malaysia 24 August 2011 Eng

TRANSMISSION MODEL AND SERIAL

Continuous Variable Transmission (CVT)

Printed in Malaysia 24 August 2011 Eng

MAJOR SPECIFICATIONS WCH000MSPEC11001

Printed in Malaysia 24 August 2011 Eng

Printed in Malaysia 24 August 2011 Eng

11A ENGINE <IAFM +>

FEAD BELT DRIVE AND TV DAMPER PULLEY .................................... 11A/3

CYLINDER HEAD GASKET ........................................................... 11A/5

CAMSHAFT AND CAMSHAFT OIL SEAL ........................................... 11A/11

TIMING BELT ........................................................................... 11A/19

CRANKSHAFT OIL SEAL .............................................................. 11A/29

ENGINE ASSEMBLY ................................................................... 11A/35

Printed in Malaysia 24 August 2011 Eng

SPECIAL TOOLS WCH11ASTOOL11001

For vehicle diagnosis, ECU, Flashing,

Printed in Malaysia 24 August 2011 Eng

FEAD BELT DRIVE AND TV DAMPER PULLEY WCH11ASASSY11001

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

Printed in Malaysia 24 August 2011 Eng

Fead belt route