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Rdce 08ma010 05 PDF
Rdce 08ma010 05 PDF
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
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.
NOTE
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
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
• 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
• ON-VEHICLE SERVICE
— Removal service point
— Installation service points
• ENGINE ASSEMBLY
— Removal and installation
— Removal service point
— Installation service points
GRP 12 – LUBRICATION
• GENERAL INFORMATION 12/2 • Update for new engine oil spe-
to 12/2 cification SAE 10W/30
• LUBRICATIONS
• 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
— Removal service point
• INTAKE MANIFOLD
— Removal service point
— Installation service point
• EXHAUST MANIFOLD
— Removal and installation
— Removal service point
— Installation service point
• EXHAUST PIPE AND MAIN MUFFLER
— Removal and installation
— 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
• TRANSMISSION ASSEMBLE
— Removal and Installation
— Removal service point
— Installation service point
• TRANSMISSION CONTROL
— Removal and Installation
— Selector lever assy
— Removal service point
— Installation service point
• TRANSMISSION ASSEMBLY
— Removal and Installation
— Removal service point
— Installation service point
• 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
— Removal and installation
— Removal service point
• WHEEL SPEED SENSOR
— Removal and installation
— Removal service point
• SRS ECU
— Removal and installation
— Removal service point
— Installation service point
• AIRBAG MODULE AND CLOCK
SPRING
— Removal and installation
— Removal service point
— Installation service point
• FRONT PASSENGER AIRBAG MODULE
— Removal and installation
— Removal service point
— Installation service point
• COMPRESSOR
— Removal and installation
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
↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
B T 3 S R J F R M A D
Symbol Description
A Transmission model number
B Transmission serial number
NOTE
Torch light is recommended to be used.
DOIMC000R11002
Symbol Description
A Proton part number
B Transmission serial number
C Supplier part number
NOTE
Torch light is recommended to be used.
DOIMC000R11001
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)
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
TOOLS
Tool Number Name Use
Flywheel
EZT 0044 To lock flywheel .
Stopper
DOIME11AR11051
DOIMC11AR07003
DOIGC11AR03021
DOIMC11AR11012
Engine oil
Non-reusable
A: O-ring
B: Delivery pipe
Pre-removal and Post-installation Operation
• 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°
Symbol Description
A Thermostat pipe assembly bolt
B Hose Clip
DOINE11AR11013
Symbol Description
A Special tool MB991653
TBS Timing belt side
DOIGC11AR03044
DOIGC11AR03045
Symbol Description
A Cylinder head
B Bushing
DOIMC11AR11002
Symbol Description
TBS Timing belt side
DOIGC11AR03048
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)
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
DOIMC11AR11019
LUBRICATION POINTS
DOIMC11AR07006
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
DOIGC11AR03034
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
Symbol Description
A Camshaft sprocket side
DOIGC11AR03035
B Intake side camshaft
C Notch
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)
Symbol Description
A Cap front area
Specified sealant :
TB1110B 2 mm (0.079 in) bead size.
DOIGE11AR03055
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.
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.
Symbol Description
A Dowel Pin
B Camshaft Intake Sprocket
C Camshaft Exhaust Sprocket
DOIME11AR11011
DOIGC11AR03034
Symbol Description
A Cam position sensor
B Bolt
DOIME11AR11055
DOIMC11AR07031
T1 : 3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 120° ± 4°
T2 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T3 : 5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 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)
Symbol Description
A Camshaft sprocket timing marks
B Cam cover
C Align dowel
D Front case
DOIMC11AR11008
Symbol Description
C Align dowel
D Front case mark
E TV damper bolt
F Special tool - EZT 0007
DOIMC11AR11004
Symbol Description
1 Special tool - EZT 0004
DOIGC11AR03165
DOIGE11AR03020
Symbol Description
A Single type socket box
B Ratchet
DOINE11AR11021 C Tensioner
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
Symbol Description
A Tensioner bearing
B core plug
C Tensioner bolt
DOINE11AR11058
DOIGE11AR03177
DOIME11AR11018
DOIME11AR11019
DOIGE11AR03024
DOIME11AR11020
DOIME11AR11021
DOIME11AR11022
Symbol Description
A Camshaft sprocket timing
marks
B Cam cover marks
C Crankshaft sprocket dowel
pin
D Front case mark
DOIME11AR11023
DOIME11AR11020
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
DOIMC11AR11018
Sealant:
Symbol Description
A Flywheel assy <CVT2>
B Damper assy <CVT2>
C Flywheel stopper (EZT0044)
DOIME11AR11043 D Damper assy <CVT2> bolts
Symbol Description
A Flywheel bolts
B Flywheel stopper (EZT0044)
C Flywheel assy <CVT2>
DOIME11AR11044
Symbol Description
A Flywheel stopper (EZT0044)
B Flywheel assy <5MTT200A>
C Flywheel bolts
DOIME11AR11045
Symbol Description
A Special tool EZT 0011
B Oil seal
C Crankshaft rear oil seal housing
D Mallet hammer
DOIHC11AR04048
Symbol Description
A Crankshaft
B Oil seal
DOIIC11AR9032
CAUTION :
Squeeze the liquid gasket uniformly so that
there is no break in the gasket nor is there
DOIGE11AR03097 too much gasket.
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)
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
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
DOIMC11AR07034
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
DOIMC11AR11016
Pre-removal Operation
• 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)
Symbol Description
A Power steering pressure line
B Power steering pressure line screw
joint
C Power steering pressure pump
DOIHC032R04004
Symbol Description
A Engine lifting link
DOIHC022R04002
12 LUBRICATION
GENERAL INFORMATION ........................................................... 12/2
ENGINE OILS ......................................................................... 12/2
Health Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/2
Recommended Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/2
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)
13A FUEL
GENERAL INFORMATION ............................................................ 13A/6
OUTLINE OF CHANGES ............................................................. 13A/6
GENERAL SPECIFICATION .......................................................... 13A/6
OUTLINE OF CHANGES
Due to the introduction of engine IAFM+ variant, the service procedure for the fuel system has been
updated.
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)
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
Items Specifications
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
TOOLS
Tool Number Name Use
Vehicle communication
EZT0047 For vehicle diagnosis
interface (VCI)
DOIMC35BR11039
DOIMC35BR11042
DOIMC35BR11041
DOIMC35BR11046
DOIMC35BR11045
DOIMC35BR11040
DOIMC35BR11043
DOIMC35BR11044
DOIMC35BR11047
TROUBLESHOOTING WCH13ASHOOT11032
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.
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
Problem
Stoppi-
symp- Starting Idling stability Driving
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
sen- sor
Cam-
∇5 ∇5 ∇8 ∇2
sha- ft
#5 #6 #7 #2
sensor
Crank-
∇6 ∇6 ∇9 ∇3
sh- aft
#6 #7 #8 #3
sen- sor
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
Problem
Stoppi-
symp- Starting Idling stability Driving
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)
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
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
Voltage Throttle Position electric position sensor
P0123 position sensor 1 high
Sensor 1 High diagnosis
Voltage Throttle Position electric position sensor
P0222 position sensor 2 low
Sensor 2 Low diagnosis
Voltage Throttle Position electric position sensor
P0223 position sensor 2 high
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
Throttle Actuator Control- ETC power stage diagnos-
P2101 short circuit
ler short circuit is
P2109
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.
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
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.
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-
P0131 Engine is running
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
DOIMC13AR11037
DOIMC13AR11030
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.
DOIMC13AR11043
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.
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
AR_RED controller out
Engine is run-
of max in PL, Lambda
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,
AR_RED controller out
Engine is run-
of max in PL, Lambda
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-
P0123 position sensor 1 high
tion Sensor 1 High the engine starts. ning
Voltage Throttle Posi- Set conditions: Engine is run-
P0222 position sensor 2 low
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
AR_RED controller out
more for 4 Engine is run-
of max in PL, Lambda
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
Throttle Actuator Con-
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
Throttle Position Sensor
lower position not Engine is run-
P2109 Lower position not
reached ning
Reached
Engine is run-
P2118 over heat protection
ning
Check condi-
Fault codes PADT-II Display Symptom Description Range of Check
tion
Throttle Actuator Con-
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
Throttle Position Sensor
upper position not Engine is run-
P2163 Upper Position not
reached ning
Reached
Throttle Position Sensor
adaptation conditions Engine is run-
P2176 Adaptation Exceed
exceeded ning
Threshold
AR_RED controller out
Engine is run-
of min in PL, Lambda
ning
between Min, MAX
P2279 Intake Air System Leak
PUT controller out of
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
AR_RED controller out
Air Leak Between MAF Engine is run-
of min in PL, Lambda
and Throttle Body ning
out of Max
AR_RED controller out
Air Leak Between MAF Engine is run-
P2281 of min in PL, Lambda
and Throttle Body ning
out of Min
PUT controller out of
Air Leak Between MAF Engine is run-
min, Lambda out of
and Throttle Body ning
MAX
Check condi-
Fault codes PADT-II Display Symptom Description Range of Check
tion
PUT controller out of
Air Leak Between MAF Engine is run-
min, Lambda out of
and Throttle Body ning
Min
AR_RED controller out
Engine is run-
of min in PL, Lambda
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
TROUBLESHOOTING PROCEDURE
DOIMC13AR11039
DOIMC13AR11002
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).
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.
Function PADT-II Display Check condition Standard value
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
TROUBLESHOOTING PROCEDURE
DOIMC13AR11038
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.
Check condi-
Fault codes PADT-II Display Symptom description Range of Check
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.
DOIMC13AR11040
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.
TROUBLESHOOTING PROCEDURE
DOIMC13AR11049
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.
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.
TROUBLESHOOTING PROCEDURE
DOIMC13AR11036
INJECTORS WCH13ASHOOT11012
DOIMC13AR11009
OPERATION
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-
Injection valve dia-
P0202 cuit/Open – Cylinder Engine is running
gnostic - open circuit
2
Injector Cir-
Injection valve dia-
P0203 cuit/Open – Cylinder Engine is running
gnostic - open circuit
3
Injector Cir-
Injection valve dia-
P0204 cuit/Open – Cylinder Engine is running
gnostic - open circuit
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
Cylinder 4 Injector Injection valve dia-
P0270 short circuit to gnostic - short circuit Engine is running
ground ground
Cylinder 4 Injector Injection valve dia-
P0271 short circuit to bat- gnostic - short circuit Engine is running
tery plus
DOIMC13AR11048
DOIMC13AR11013
OPERATION
The fuel pump is driven when the engine is cranking and running.
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.
TROUBLESHOOTING PROCEDURE
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.
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).
Function PADT-II Display Check condition Standard value
Catalyst damaging misfire
cylinder 1
Catalyst damaging misfire
cylinder 2
Catalyst damaging misfire
Dynamic Display Engine runs at idle 0 ~ 65535
cylinder 3
Catalyst damaging misfire
cylinder 4
Catalyst damaging misfire
potential
TROUBLESHOOTING PROCEDURE
DOIMC13AR11034
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.
Check condi-
Fault codes PADT-II Display Symptom description Range of Check
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.
Function PADT-II Display Check condition Standard value
Dynamic Display Anti Knock Control Status Ignition On OFF / ON
TROUBLESHOOTING PROCEDURE
DOIMC13AR11041
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.
Check condi-
Fault codes PADT-II Display Symptom description Range of Check
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
DOIMC13AR11010
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-
Fault codes PADT-II Display Symptom description Range of Check
tion
Ignition Coil 1 open cir- Engine is run-
P0351
cuit ning
Ignition Coil 2 open cir- Engine is run-
P0352
cuit ning
Open circuit
Ignition Coil 3 open cir- Engine is run-
P0353
cuit ning
Ignition Coil 4 open cir- Engine is run-
P0354 • Engine speed is ap-
cuit ning
prox. 500-4000
Ignition Coil 1 short cir- r/min . Engine is run-
P2300 Short circuit to ground
cuit to ground • Engine is not ning
Ignition Coil 1 short cir- cranking. Engine is run-
P2301 Short circuit to plus
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-
P2306 Short circuit to ground
cuit to ground ning
Ignition Coil 4 short cir- Engine is run-
P2307 Short circuit to plus
cuit to battery ning
Ignition Coil 2 short cir- Engine is run-
P2309 Short circuit to ground
cuit to ground ning
Ignition Coil 2 short cir- Engine is run-
P2310 Short circuit to plus
cuit to battery ning
Function PADT-II Display Check condition Standard value
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
TROUBLESHOOTING PROCEDURE
DOIMC13AR11046
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.
DOIMC13AR11035
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.
Check Ccondi-
Fault codes PADT-II Display Symptom description Range of Check
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) .
Function PADT-II Display Check condition Standard value
Ign on 0.00 %
Dynamic Display Purge Duty Cycle
Engine runs at idle 0.04 %
Function PADT-II Display Check condition Standard value
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
TROUBLESHOOTING PROCEDURE
DOIMC13AR11051
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.
Check condi-
Fault codes PADT-II Display Symptom description Range of Check
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
Function PADT-II Display Check condition Standard value
Sound of operation can
Actuator Test Fan 1 Ignition ON be heard when purge
valve is driven
TROUBLESHOOTING PROCEDURE
DOIMC13AR11045
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.
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).
Function PADT-II Display Check condition Standard value
Dynamic Display Vehicle Speed Ignition ON 0 km/h (0 mph)
TROUBLESHOOTING PROCEDURE
DOIMC13AR11059
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.
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).
Function PADT-II Display Check condition Standard value
Dynamic Display Vehicle Speed Ignition ON 0 km/h (0 mph)
TROUBLESHOOTING PROCEDURE
DOIMC13AR11060
DOIMC13AR11018
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-
Fault codes PADT-II Display Symptom description Range of Check
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.
TROUBLESHOOTING PROCEDURE
DOIMC13AR11058
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.
Symptom descrip-
Fault codes PADT-II Display Range of Check Check condition
tion
Engine speed at idle is below Present ISC_LOW • Ignition switch:
P0506 Engine is running
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.
P0507 Engine is running
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).
Function PADT-II Display Check condition Standard value
Engine run at idle, a/c off ± 850 rpm
Dynamic Display Engine speed
Engine run at idle, a/c on ± 850 rpm
TROUBLESHOOTING PROCEDURE
DOIKC13AR09043
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.
Symptom descrip-
Fault codes PADT-II Display Range of Check Check condition
tion
Engine speed at idle is below Present ISC_LOW • Ignition switch:
P0506 Engine is running
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.
P0507 Engine is running
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).
Function PADT-II Display Check condition Standard value
Engine run at idle, a/c off ± 750 rpm
Dynamic Display Engine speed
Engine run at idle, a/c on ± 750 rpm
TROUBLESHOOTING PROCEDURE
DOIKC13AR09043
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-
Fault codes PADT-II Display Symptom description Range of Check
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
TROUBLESHOOTING PROCEDURE
DOIMC13AR11057
DOIMC13AR11020
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
TROUBLESHOOTING PROCEDURE
DOIMC13AR11052
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.
TROUBLESHOOTING PROCEDURE
DOINC13AR09079
DOIMC13AR11011
OPERATION
The starter control is driven when the engine is cranking and while the engine is running.
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
TROUBLESHOOTING PROCEDURE
DOIMC13AR11050
DOIMC13AR11104
OPERATION
Engine ECU check to throttle position sensor, pedal voltage sensor, TMAP sensor and Camshaft sensor
power voltage for abnormal.
Check condi-
Fault codes PADT-II Display Symptom description Range of Check
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
TROUBLESHOOTING PROCEDURE
DOIMC13AR11105
DOIMC13AR11019
OPERATION
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.
TROUBLESHOOTING PROCEDURE
DOIMC13AR11054
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.
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 .
Function PADT-II Display Check condition Standard value
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
TROUBLESHOOTING PROCEDURE
DOIMC13AR11053
DOIMC13AR11103
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.
TROUBLESHOOTING PROCEDURE
DOIMC13AR11033
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-
Fault codes PADT-II Display Range of check Check condition
tion
One of the follow-
ing causes may be
suspected:
• No power
supply to
CVT.
• Defective of
Transmission control unit Transmission limp transmission
P0700 Engine is running
limp home diagnosis home unit -CVT.
• CAN bus is off
• CAN ECU
communica-
tion failed
• CAN engine
torque signal
error
Function PADT-II Display Check condition Standard value
Dynamic Display Gear Lever Position Ignition ON D / P/N
TROUBLESHOOTING PROCEDURE
DOIMC13AR11112
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-
Fault codes PADT-II Display Symptom description Range of Check
tion
• Ignition switch ON
position
P0850 P/N switch Plausibility Plausible Value Ignition ON
• Can voltage measure-
ment 0~3 V
DOIMC13AR11101
DOIMC13AR11061
OPERATION
The engine ECU detects that accelerator pedal and brake pedal are both pressed for a calculated
amount of time.
Check condi-
Fault codes PADT-II Display Symptom description Range of Check
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
Function PADT-II Display Check condition Standard Value
Engine Idling (No Load) 0%
Dynamic Display Accelerator pedal position
Engine Idling (Full Throttle) 100%
TROUBLESHOOTING PROCEDURE
DOIMC13AR11102
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.
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
Error in the respect-
CAN Diagnosis - Lost • Check the wiring
ive Control Unit (CU)
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.
CAN Diagnosis - Lost
ive Control Unit (CU)
U0121 Communication Engine is running
communicating on
with ABS/ESP
the CAN-HS bus
Error in the respect-
CAN Diagnosis - Lost
ive Control Unit (CU)
U0140 Communication Engine is running
communicating on
with meter cluster
the CAN-HS bus
TROUBLESHOOTING PROCEDURE
DOIMC13AR11056
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
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”.
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
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.
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.
DOIMC13AR11066
DOIMC13AR11067
DOIMC13AR11068
DOIMC13AR11069
DOIMC13AR11070
DOIMC13AR11071
DOIMC13AR11072
DOIMC13AR11073
DOIMC13AR11074
DOIMC13AR11075
DOIMC13AR11076
DOIMC13AR11077
DOIMC13AR11078
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.
DOIMC13AR11080
Surge
Surge Probable cause
• Malfunction of the ignition system.
Defective ignition system, abnormal air-fuel ratio, etc. • Malfunction of air-fuel ratio control sys-
are suspected. tem.
• Injectors do not work.
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
DOIMC13AR11082
Dieseling
Dieseling Probable cause
Fuel leakage from injectors is suspected. • Fuel leakage from injectors.
DOIHC13AR05148
DOIMC13AR11083
DOIMC13AR07226
DOIMC13AR11084
DOIMC13AR11085
DOIMC13AR11086
DOIMC13AR11106
DOIMC13AR11087
DOIMC13AR11088
DOIMC13AR11089
DOIMC13AR11090
DOIMC13AR11091
DOIMC13AR11092
DOINC13AR09081
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
DOIMC13AR11093
DOIMC13AR11094
DOIMC13AR11094
DOIMC13AR11095
DOIMC13AR11096
DOIMC13AR11097
DOIMC13AR11098
DOIMC13AR11099
DOIMC13AR11100
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.
DOIMC13AR11032
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
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
91 – 63 Injector – 2
12.0 Ω ± 2.4 Ω
77 – 63 Injector – 3
92 – 63 Injector – 4
48 – 63 Ignition coil – 1
80 – 63 Ignition coil – 2
Less than1.0 Ω
96 – 63 Ignition coil – 3
64 – 63 Ignition coil – 4
ECU WCH13ASASSY11002
DOIMC13AR11109
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
DOIMC023R11176
DOIMC023R11183
DOIMC023R11184
DOIMC023R11185
INJECTOR WCH13ASASSY11001
DOIME11AR11005
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.
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
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
Symbol Description
B Injector
C Fuel rail
DOINE11AR11039
Symbol Description
D Injector clip
E Injector slot
DOIME13BR07006
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.
Symbol Description
DOIMC015R07017
A Battery cable
B Insulating tape
C Battery
DISCONNECT CONNECTOR
Disconnect the harness connector at engine room
(Refer to 15/2 ).
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.
Symbol Description
A Injector harness connector
B Lock pin
DOIMC015R11010
Symbol Description
C Fuel rail assy
D Bolt
DOIMC015R11019
Symbol Description
E Lifting eye
DOIMC015R11028
Symbol Description
C Fuel rail assy
F Injector
CAUTION
Be careful not to drop the injector.
DOIMC015R11011
DOIMC015R11002
Non-reusable parts
Pre-removal Operation
• Fuel discharge prevention (GROUP 13–Fuel)
• Air cleaner removal (GROUP 15–Intake & Exhaust)
• Throttle body removal (GROUP 13–Fuel)
Post-installation Operation
• 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
T1 : 0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.05 kgm (0.5 Nm, 0.36 ft.lbs)
T2 : 2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
T3 : 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
T4 : 5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs)
T5 : 0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.05 kgm (0.5 Nm, 0.36 ft.lbs)
T6 : 0.45 kgm (4.5 Nm, 3.25 ft.lbs) ± 0.05 kgm (0.5 Nm, 0.36 ft.lbs)
T7 : 0.45 kgm (4.5 Nm, 3.25 ft.lbs) ± 0.05 kgm (0.5 Nm, 0.36 ft.lbs)
T8 : 2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.5 kgm (5 Nm, 3.62 ft.lbs)
Symbol Description
A Upper bracket bolt
B Intake manifold
DOIMC015R11015
Symbol Description
B Intake manifold
C Flange bolt
D Nut
DOIMC015R11016
Symbol Description
B Intake manifold
DOIMC015R11021
Symbol Description
A Gasket
B Intake manifold
C Groove
DOIGE11AR06052
Symbol Description
B Intake manifold
D Cylinder head
DOIMC015R11022
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
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
.
Symbol Description
C Fuel rail assy
F Injector
CAUTION
Be careful not to drop the injector and torn
the injector’s O-ring.
DOIMC015R11011
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
Symbol Description
E Lifting eye
Specified torque (E):
2.2 ~ 2.6 kgm (22 ~ 26 Nm, 15.91 ~ 18.81
ft.lbs)
DOIMC015R11028
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) :
Symbol Description
Oxygen sensor harness connect-
A
or
DOIMC015R11023
Symbol Description
B Heat shield
C Bolt
DOIMC015R11024
Symbol Description
Oxygen sensor harness connect-
A
or
B Heat shield
DOIMC015R11017
Symbol Description
C Bolt
D Catalytic converter
E Bracket
DOIMC015R11025
Symbol Description
F Exhaust manifold
G Nut catalytic converter
DOIMC015R11026
Symbol Description
F Exhaust manifold
H Nut
DOIMC015R11006
Symbol Description
D Catalytic converter
F Exhaust manifold
DOIMC015R11012
Symbol Description
F Exhaust manifold
I Cylinder head stud
DOIMC015R11018
Symbol Description
A Gasket
B Stud
DOIMC015R11007
Symbol Description
A Gasket
B Stud
C Exhaust manifold
DOIMC015R11020
DOIMC015R11013
Symbol Description
D Catalytic converter
E Catalytic converter bracket
F Bolt
DOIMC015R11005
Symbol Description
C Exhaust manifold
D Catalytic converter
G Nut
DOIMC015R11004
Symbol Description
H Heat shield
F Bolt
DOIMC015R11027
DOIMC015R11008
— Non-reusable parts
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)
NOTE
21 CLUTCH
CLUTCH CONTROL (5MTT200A) .................................................... 21/2
DOIMC021R11001
Symbol:
— Non-reusable parts
— 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
Symbol Description
A Hose assy clutch
B Cylinder assy,clutch master
C Retainer clip
DOIMC021R11003
Symbol Description
D Brake line
E 3rd slot from top
F Clip
G Fit hose into clip slot
DOIMC021R11004
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
DOIMC021R11006
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.
22 MANUAL TRANSMISSION
SPECIFICATIONS ....................................................................... 22/2
GEAR RATIO .......................................................................... 22/2
5MTT200A (1.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/2
5MTT200A (1.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/2
LUBRICANT .......................................................................... 22/2
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)
TOOLS
Tool Number Name Use
DOIMT22DR11012
DOIGE11AR03105
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
(PUB. NO. RDWE-08MA010).
4. Remove the lover arm ball joint connection
bolt refer to GROUP 33A – Lower Arm (PUB.
NO. RDWE-08MA010).
DOIMC022R11036
DOIMC022R11037
DOIMC022R11038
DOIMC023R11042
DOIMC022R11001
DOIMC022R11002
DOIMC022R11007
1. Place the car on a flat ground.
DOIMC032L08012
DOIMC022R11004
DOIMC022R11003
DOIMC022R11005
DOIMC022R11006
DOIMC022R11001
DOIMC022R11002
DOIMC022R11007
DOIMC022R11035
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.
DOIMC022R11008
DOIMC022R11009
DOIMC022R11010
DOIMC022R11011
DOIMC022R11012
DOIMC022R11013
DOIMC022R11014
DOIMC022R11015
DOIMC022R11016
DOIMC022R11017
DOIMC022R11018
DOIMC022R11019
DOIMC022R11020
DOIMC022R11014
DOIMC022R11015
DOIMC022R11016
DOIMC022R11017
DOIMC022R11039
DOIMC022R11040
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
T1 : 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
DOIMC022R11041
— Non-reusable parts
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).
DOIMC022R11021
DOIMC022R11042
DOIMC022R11022
DOIMC022R11043
DOIMC022R11023
DOIMC022R11028
DOIMC032L08012
DOIMC022R11004
DOIMC022R11008
DOIMC022R11009
DOIMC022R11024
DOIMC022R11036
DOIMC023R11026
DOIMC022R11026
DOIMC022R11027
DOIMC023R11020
DOIMC023R11021
DOIMC023R11022
DOIMC023R11023
DOIMC023R11024
DOIMC023R11013
DOIMC022R11029
DOIMC022R11030
DOIMC022R11044
DOIMC022R11031
AIR-CLEANER INSTALLATION
NOTE:
Detail service procedure for install the Air-
cleaner, refer to GROUP 015 – Air-cleaner (PUB.
NO. RDWE-08MA010).
NOTE
23 CVT
GENERAL INFORMATION ............................................................ 23/8
OUTLINE OF CHANGES ............................................................. 23/8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/108
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/109
P0902: EDS3 (CLUTCH) SHORT CIRCUIT TO GROUND ........................ 23/111
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/111
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/112
P0903: EDS3 (CLUTCH) SHORT CIRCUIT TO BATTERY ........................ 23/114
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/114
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/115
P0900: EDS3 (CLUTCH) OPEN CIRCUIT .......................................... 23/117
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/117
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/118
P1761: EDS CURRENT FAULT ...................................................... 23/119
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/119
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/120
P1762: CURRENT STUCK ........................................................... 23/121
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/121
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/122
P0930: SHIFT LOCK SHORT CIRCUIT TO GROUND ............................ 23/124
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/124
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/125
P0931: SHIFT LOCK SHORT CIRCUIT TO BATTERY OR OPEN CIRCUIT ..... 23/127
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/127
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/130
P1768: BACKLIGHT SHORT CIRCUIT TO GROUND ............................ 23/132
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/132
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/133
P1769: BACKLIGHT SHORT CIRCUIT TO BATTERY OR OPEN CIRCUIT ..... 23/134
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/134
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/136
P0868: OPERATION READINESS TIME OUT ..................................... 23/137
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/137
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/137
P0811: CLUTCH (FORWARD OR REVERSE) SLIPPING ......................... 23/138
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/138
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/138
P2787: CLUTCH TEMPERATURE TOO HIGH .................................... 23/139
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/139
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/139
P0730: RATIO CONTROL FAULT .................................................. 23/140
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/140
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/141
P1770: ENGINE SPEED TOO LOW ................................................ 23/143
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/143
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/143
P0727: HARDWIRED ENGINE SPEED UNPLAUSIBLE .......................... 23/144
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/144
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/145
P0219: POWERTRAIN SPEED OUT OF RANGE ................................. 23/146
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/146
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/146
P0944: INSUFFICIENT CLAMPING FORCE (VSM) ............................... 23/146
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/146
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/147
P1772: AT MODE SIGNAL ERROR ................................................ 23/149
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/149
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/150
P080A: EOL CLUTCH ADAPTATION NOT FINISHED ........................... 23/152
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/152
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/152
P1774: END OF LINE (EOL) CLUTCH ADAPTATION ERROR .................. 23/152
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/152
NOTE
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.
SPECIFICATIONS WCH023SPECS11002
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)
TOOLS
Tool Number Name Use
DOIIT23CR09010
DOIIT23CR09009
DOIIT23CR09004
DOINT23CR11032
DOINT23CR11030
DOIMT22DR10152
EZT 0047
Vehicle communication
For vehicle diagnosis
interface (VCI)
DOIMC35BR11039
DOIMC35BR11042
DOIMC35BR11041
DOIMC35BR11046
DOIMC35BR11045
DOIMC35BR11040
DOIMC35BR11043
DOIMC35BR11044
DOIMC35BR11047
TROUBLESHOOTING WCH023TSHOT11029
DOIMC023R11072
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
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.
How to check and repair:
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:
DOIMC023R11123
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
SHOCKS
Problem description:
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).
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
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.
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.
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.
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.
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.
DOIMC023R11272
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.
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.
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
1. Short circuit to ground
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
1. Short circuit to ground
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
5. Vehicle cable harness
problem
Dia-
gnosis Diagnosis PADT-II Dis-
No Probable cause Reaction from TCU
Code Item play
No
1. Short circuit to ground
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
1. Short circuit to ground
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
6. Hydraulic unit defective
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
5. Oil pump defective
1. Short circuit to ground
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
2. Vehicle cable harness
13 P0706 Drive mode sensor single 2. Substitute lever posi-
problem
sensor line error tion
3. Drive mode sensor failure
4. TCU malfunction
1. Transmission cable harness
problem
Drive mode
2. Vehicle cable harness 1. High side off
14 P0705 sensor multiple
problem 2. Warning lamp
lines error
3. Drive mode sensor failure
4. TCU malfunction
Dia-
gnosis Diagnosis PADT-II Dis-
No Probable cause Reaction from TCU
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
1. Short circuit to ground
Circuit to 1. High side off
16 P0658 2. Open circuit
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
Battery or high 1. Battery problem
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)
Dia-
gnosis Diagnosis PADT-II Dis-
No Probable cause Reaction from TCU
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)
2. Hydraulic unit defective 2. Warning lamp
Open Circuit
EDS3 (clutch)
1. Short circuit to ground 1. High side off
27 P0902 Short Circuit to
2. Hydraulic unit defective 2. Warning lamp
Ground
EDS3 (clutch)
1. Short circuit to battery 1. High side off
28 P0903 Short Circuit to
2. Hydraulic unit defective 2. Warning lamp
Battery
EDS3 (clutch) 1. Open circuit 1. High side off
29 P0900
Open Circuit 2. Hydraulic unit defective 2. Warning lamp
1. Transmission cable harness
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
1. Short circuit to ground 1. High side off
32 P0930 Circuit to
2. TCU malfunction 2. Warning lamp
Ground
Shift lock Shift lock Short
1. Short circuit to battery
Circuit to Bat- 1. High side off
33 P0931 2. Open circuit
tery or Open 2. Warning lamp
3. TCU malfunction
Circuit
Dia-
gnosis Diagnosis PADT-II Dis-
No Probable cause Reaction from TCU
Code Item play
No
Backlight Short
1. Short circuit to ground 1. High side off
34 P1768 Circuit to
2. TCU malfunction 2. Warning lamp
Ground
Backlight Backlight Short
1. Short circuit to battery
Circuit to Bat- 1. High side off
35 P1769 2. Open circuit
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
4. Hydraulic unit defective
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
4. Hydraulic unit defective
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
1. Oil level problem
2. Oil type problem
Ratio control 1. High side off
39 P0730 Ratio control 3. Sensor or hydraulic unit
fault 2. Warning lamp
defective
4. Oil pump 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
Dia-
gnosis Diagnosis PADT-II Dis-
No Probable cause Reaction from TCU
Code Item play
No
1. Torque of the engine is
too big
2. ECU malfunction
3. Oil level problem
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
7. Hydraulic unit defective
8. Oil pump defective
1. Short circuit to battery
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
Dia-
gnosis Diagnosis PADT-II Dis-
No Probable cause Reaction from TCU
Code Item play
No
1. Warning lamp
2. Emergency mode act-
ive
3. No manual mode
4. Increased clamping
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
1. Increased clamping
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
5. Substitute rear left
wheel speed
6. Substitute rear right
wheel speed
CAN ECU com- 1. Engine controller failure
52 U0100 munication 2. CAN connection problem
failed from engine controller
Dia-
gnosis Diagnosis PADT-II Dis-
No Probable cause Reaction from TCU
Code Item play
No
1. Warning lamp
2. Emergency mode act-
ive
3. No manual mode
4. Increased clamping
level 0
5. Activate internal
driving strategy
6. Substitute engine
speed
7. Substitute engine
torque
8. Substitute engine
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
2. Emergency mode act-
ive
CAN engine
3. No manual mode
55 U1014 torque signals EMS controller problem
4. Activate internal
error
driving strategy
5. Substitute engine
torque
1. Increased clamping
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
1. Increased clamping
level 0
CAN wheel 1. Wheel speed sensor defect- 2. Substitute detection
57 U1017 speed error - ive function of blocked
front right 2. Sensor wiring problem and spinning wheels
3. Substitute front right
wheel speed
58 U1018
Dia-
gnosis Diagnosis PADT-II Dis-
No Probable cause Reaction from TCU
Code Item play
No
1. Increased clamping
level 0
CAN wheel 1. Wheel speed sensor defect- 2. Substitute detection
speed error - ive function of blocked
rear left 2. Sensor wiring problem and spinning wheels
3. Substitute rear left
wheel speed
1. Increased clamping
level 0
CAN wheel 1. Wheel speed sensor defect- 2. Substitute detection
59 U1019 speed error - ive function of blocked
rear right 2. Sensor wiring problem and spinning wheels
3. Substitute rear right
wheel speed
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%
No Conditions for Test/Operation Judgement Check item Diagnos- Reference for checking
test/operation standard is code procedure in case of er-
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 )
No Conditions for Test/Operation Judgement Check item Diagnos- Reference for checking
test/operation standard is code procedure in case of er-
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 in- complete 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
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
Diagnosis
No Diagnostic Item Reference Page
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
Diagnosis
No Diagnostic Item Reference Page
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
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
DOIMC023R11229 DOIMC023R11230
DOIMC023R11254
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Short circuit to ground
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
DOIMC023R11124
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
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
High oil temperat-
P0218 Warning lamp Oil cooler problem
ure
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).
DOIMC023R11202
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
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Oil cooler problem
Critical oil temper- 1. High side off 2. Oil level problem
P1767
ature 2. Warning lamp 3. Hydraulic unit defective
DOIMC023R11203
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
DOIMC023R11229 DOIMC023R11230
DOIMC023R11235
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Short circuit to ground
2. Short circuit to battery
Primary pulley 1. High side off 3. Open circuit
P2765
speed sensor fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction
DOIMC023R11125
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.
DOIMC023R11197
DOIMC023R11229 DOIMC023R11230
DOIMC023R11243 DOIMC023R11235
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
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
DOIMC023R11206
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
changes abruptly or when there is a discrepancy between this sensor and other sensors in sensor
reading.
DOIMC023R11189
DOIMC023R11229 DOIMC023R11230
DOIMC023R11255
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Short circuit to ground
2. Short circuit to battery
Secondary pulley 1. High side off 3. Open circuit
P0720
speed sensor fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction
DOIMC023R11126
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
changes abruptly or when there is a discrepancy between this sensor and other sensors in sensor
reading.
DOIMC023R11197
DOIMC023R11229 DOIMC023R11230
DOIMC023R11243 DOIMC023R11255
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
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
DOIMC023R11205
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
DOIMC023R11229 DOIMC023R11230
DOIMC023R11253
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Short circuit to ground
2. Short circuit to battery
Secondary pressure 1. High side off 3. Open circuit
P0840
sensor fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction
DOIMC023R11127
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
DOIMC023R11229 DOIMC023R11230
DOIMC023R11253
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Short circuit to ground
2. Short circuit to battery
Pressure sensor supply 1. High side off 3. Open circuit
P0641
fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction
DOIMC023R11142
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.
DOIMC023R11253
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Too low pressure
2. Oil level problem
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
6. Hydraulic unit defective
7. Oil pump defective
DOIMC023R11162
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.
DOIMC023R11253
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Too high pressure
2. Oil level problem
Secondary pulley 1. High side off 3. Oil type problem
P1766
pressure too high 2. Warning lamp 4. Hydraulic unit defective
5. Oil pump defective
DOIMC023R11171
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
DOIMC023R11229 DOIMC023R11230
DOIMC023R11236 DOIMC023R11235
DOIMC023R11255
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Short circuit to ground
2. Short circuit to battery
DMS and speed sensor 1. High side off 3. Open circuit
P0651
supply fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction
DOIMC023R11143
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.
DOIMC023R11236
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Transmission cable harness
problem
Drive mode sensor 1. Warning lamp 2. Vehicle cable harness
P0706 problem
single line error 2. Substitute lever position
3. Drive mode sensor failure
4. TCU malfunction
DOIMC023R11226
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.
DOIMC023R11236
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Transmission cable harness
problem
Drive mode sensor 1. High side off 2. Vehicle cable harness
P0705 problem
multiple lines error 2. Warning lamp
3. Drive mode sensor failure
4. TCU malfunction
DOIMC023R11227
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
DOIMC023R11229 DOIMC023R11230
DOIMC023R11256 DOIMC023R11257
DOIMC023R11258
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
High side Short 1. High side off 1. Short circuit to battery
P0659 2. TCU malfunction
Circuit to Battery 2. Warning lamp
DOIMC023R11131
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
DOIMC023R11229 DOIMC023R11230
DOIMC023R11256 DOIMC023R11257
DOIMC023R11258
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Short circuit to ground
High side Short 1. High side off 2. Open circuit
P0658
Circuit to Battery 2. Warning lamp 3. TCU malfunction
DOIMC023R11130
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).
DOIMC023R11256 DOIMC023R11257
DOIMC023R11258
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
Double fault re-
1. High side off
P0701 quiring high side TCU malfunction
2. Warning lamp
open
Function PADT–II display Check condition Standard value
Dynamic data High side voltage > 3.4 V
Ignition ON
display Battery voltage 11.6 - 12.0 V
DOIMC023R11168
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). It monitors if power supply system is normal (3.4 V).
DOIMC023R11199
DOIMC023R11229 DOIMC023R11230
DOIMC023R11238 DOIMC023R11240
DOIMC023R11256 DOIMC023R11257
DOIMC023R11258
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
Battery or high 1. Battery problem
1. High side off 2. Highside problem
P0822 side voltage too
2. Warning lamp 3. TCU malfunction
low
DOIMC023R11212
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). It monitors if power supply system is normal (3.4 V).
DOIMC023R11199
DOIMC023R11229 DOIMC023R11230
DOIMC023R11238 DOIMC023R11240
DOIMC023R11256 DOIMC023R11257
DOIMC023R11258
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
Battery or high 1. Battery problem
1. High side off 2. Highside problem
P0883 side voltage too
2. Warning lamp 3. TCU malfunction
high
DOIMC023R11213
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.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
Watchdog test 1. High side off
P0702 TCU malfunction
failed (during init) 2. Warning lamp
DOIMC023R11132
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
DOIMC023R11229 DOIMC023R11230
DOIMC023R11256
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
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
Function PADT–II display Check Condition Standard Value
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
DOIMC023R11133
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
DOIMC023R11229 DOIMC023R11230
DOIMC023R11256
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
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
Function PADT–II display Check Condition Standard Value
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
DOIMC023R11134
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
DOIMC023R11229 DOIMC023R11230
DOIMC023R11256
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
EDS1 (primary pul- 1. High side off 1. Open circuit
P0960 2. Hydraulic unit defective
ley) open circuit 2. Warning lamp
DOIMC023R11135
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 secondary pressure regulator
valve.
DOIMC023R11192
DOIMC023R11229 DOIMC023R11230
DOIMC023R11257
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
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
Function PADT–II display Check Condition Standard Value
1. C o m m a n d e d 1. Warming up
current of Pul- 2. Drive for 15 minutes or
ley 2 Pressure more so that the transmis-
Pulley 2 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
2 Pressure Reg-
ulator
DOIMC023R11136
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 secondary pressure regulator
valve.
DOIMC023R11192
DOIMC023R11229 DOIMC023R11230
DOIMC023R11257
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
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
Function PADT–II display Check Condition Standard Value
1. C o m m a n d e d 1. Warming up
current of Pul- 2. Drive for 15 minutes or
ley 2 Pressure more so that the transmis-
Pulley 2 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
2 Pressure Reg-
ulator
DOIMC023R11137
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 secondary pressure regulator
valve.
DOIMC023R11192
DOIMC023R11229 DOIMC023R11230
DOIMC023R11257
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
EDS2 (secondary 1. Open circuit
1. High side off
P0964 pulley) open cir- 2. Hydraulic unit defective
2. Warning lamp
cuit
Function PADT–II display Check Condition Standard Value
1. C o m m a n d e d 1. Warming up
current of Pul- 2. Drive for 15 minutes or
ley 2 Pressure more so that the transmis-
Pulley 2 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
2 Pressure Reg-
ulator
DOIMC023R11138
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 clutch pressure regulator valve.
DOIMC023R11192
DOIMC023R11229 DOIMC023R11230
DOIMC023R11258
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
EDS3 (clutch) short 1. High side off 1. Short circuit to ground
P0902 2. Hydraulic unit defective
circuit to Ground 2. Warning lamp
DOIMC023R11139
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 clutch pressure regulator valve.
DOIMC023R11192
DOIMC023R11229 DOIMC023R11230
DOIMC023R11258
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
EDS3 (clutch) short 1. High side off 1. Short circuit to battery
P0903 2. Hydraulic unit defective
circuit to Battery 2. Warning lamp
DOIMC023R11140
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 clutch pressure regulator valve.
DOIMC023R11192
DOIMC023R11229 DOIMC023R11230
DOIMC023R11258
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
EDS3 (clutch) open 1. High side off 1. Open circuit
P0900 2. Hydraulic unit defective
circuit 2. Warning lamp
DOIMC023R11141
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 pressure regulator current.
DOIMC023R11256 DOIMC023R11257
DOIMC023R11258
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Transmission cable harness
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
DOIMC023R11224
OPERATION
A pressure regulator is a valve that automatically cuts 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.
DOIMC023R11256 DOIMC023R11257
DOIMC023R11258
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. High side off
P1762 Current stuck TCU malfunction
2. Warning lamp
DOIMC023R11211
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
DOIMC023R11240 DOIMC023R11238
DOIMC023R11230 DOIMC023R11246
DOIMC023R11244 DOIMC023R11241
DOIMC023R11233 DOIMC023R11232
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
Shift lock short cir- 1. High side off 1. Short circuit to ground
P0930 2. TCU malfunction
cuit to Ground 2. Warning lamp
DOIMC023R11164
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.
DOIMC023R11194
DOIMC023R11230 DOIMC023R11246
DOIMC023R11244 DOIMC023R11241
DOIMC023R11240 DOIMC023R11251
DOIMC023R11238 DOIMC023R11239
DOIMC023R11233 DOIMC023R11232
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
Shift lock short cir- 1. Short circuit to battery
1. High side off 2. Open circuit
P0931 cuit to Battery or
2. Warning lamp 3. TCU malfunction
open circuit
DOIMC023R11163
OPERATION
CVT-TCU detects malfunction using the backlight switch signal sent from the engine ECU.
DOIMC023R11195
DOIMC023R11230 DOIMC023R11242
CONNECTOR: C-17
DOIMC023R11246
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
Backlight short cir- 1. High side off 1. Short circuit to ground
P1768 2. TCU malfunction
cuit to Ground 2. Warning lamp
DOIMC023R11165
OPERATION
CVT-TCU detects malfunction using the backlight switch signal sent from the engine ECU.
DOIMC023R11196
DOIMC023R11230 DOIMC023R11246
DOIMC023R11242 DOIMC023R11238
CONNECTOR: A-19
DOIMC023R11239
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
Backlight short cir- 1. Short circuit to battery
1. High side off 2. Open circuit
P1769 cuit to Battery or
2. Warning lamp 3. TCU malfunction
open circuit
DOIMC023R11167
OPERATION
Operation readiness is the end state of operation planning.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Oil level problem
Operation readi- 1. High side off 2. Oil type problem
P0868 3. Oil pump defective
ness time out 2. Warning lamp
4. Hydraulic unit defective
DOIMC023R11169
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.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
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
4. Hydraulic unit defective
DOIMC023R11166
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.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Oil level problem
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
DOIMC023R11214
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.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Oil level problem
2. Oil type problem
1. High side off 3. Sensor or hydraulic unit de-
P0730 Ratio control fault
2. Warning lamp fective
4. Oil pump defective
DOIMC023R11170
OPERATION
The engine speed signal is transmitted from engine ECU to CVT-TCU via CAN communication line.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Idle speed controller problem
Engine speed too 2. Check engine problem
P1770 Warning lamp
low 3. Throttle body problem
DOIMC023R11210
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
DOIMC023R11243 DOIMC023R11230
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Engine problem
Hardwired engine 2. Sensor defective
P0727 Warning lamp
speed unplausible 3. TCU malfunction
DOIMC023R11223
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.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
Powertrain speed 1. High side off
P0219 Fuel cut off problem
out of range 2. Warning lamp
Function PADT–II display Check Condition Standard Value
1. Warming up
2. Drive for 15 minutes or
Dynamic data
Engine speed more so that the transmis- ±850 rpm (Idling)
display
sion oil temperature be-
comes 70-90 °C (158-194 °F).
DOIMC023R11204
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).
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Torque of the engine is too
big
2. ECU malfunction
3. Oil level problem
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
7. Hydraulic unit defective
8. Oil pump defective
DOIMC023R11207
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
DOIMC023R11251 DOIMC023R11230
DOIMC023R11244 DOIMC023R11246
SAT SWITCH
DOIMC023R11234
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Short circuit to battery
AT mode signal er- 2. Open circuit
P1772 Warning lamp 3. Stepper motor switch mal-
ror
function
DOIMC023R11208
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.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
EOL clutch adapta-
P080A Warning lamp Clutch adaptation not complete
tion not finished
Function PADT–II display Check Condition Standard Value
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
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.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
End of Line (EOL)
P1774 clutch adaptation Warning lamp Clutch adaptation error
error
Function PADT–II display Check Condition Standard Value
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
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
DOIMC023R11249 DOIMC023R11230
DOIMC023R11239 DOIMC023R11240
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Brake signal wiring problem
1. Warning lamp 2. Brake switch problem
P0571 Brake signal error
2. Brake signal on 3. TCU malfunction
DOIMC023R11228
OPERATION
The fault code is sets when the configuration between two or more modules do not match.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
Vehicle configura- 1. High side off Invalid combination of TCU
U0301
tion mismatch 2. Warning lamp hardware and software
DOIMC023R11225
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.
DOIMC023R11282
DOIMC023R11244 DOIMC023R11264
DOIMC023R11265 DOIMC023R11266
CONNECTOR: A-43
DOIMC023R11267
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Increased clamping level 0
2. Substitute detection func-
U0415 ABS function error ABS system problem
tion of blocked and spin-
ning wheels
DOIMC023R11215
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
DOIMC023R11230 DOIMC023R11268
DOIMC023R11245 DOIMC023R11246
CONNECTOR: D-06
DOIMC023R11248
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Warning lamp
2. Emergency mode active
3. No manual mode
4. Increased clamping level 1
(highest)
5. Substitute detection func-
tion of blocked and spin-
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
DOIMC023R11216
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.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Increased clamping level 0
2. Substitute detection func-
tion of blocked and spin-
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
5. Substitute rear left wheel
speed
6. Substitute rear right wheel
speed
DOIMC023R11217
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.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Warning lamp
2. Emergency mode active
3. No manual mode
4. Increased clamping level 0
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
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.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
CAN engine speed 1. Warning lamp 1. Motor speed sensor defective
U1012 2. Sensor wiring problem
signal error 2. Substitute engine speed
DOIMC023R11219
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.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Warning lamp 1. Accelerator pedal sensor de-
CAN accelerator fective
U1013 2. Accelerator pedal value
pedal signal error 2. Sensor wiring problem
fixed
DOIMC023R11220
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.
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Warning lamp
2. Emergency mode active
CAN engine 3. No manual mode
U1014 EMS controller problem
torque signal error 4. Activate internal driving
strategy
5. Substitute engine torque
Function PADT–II display Check Condition Standard Value
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
OPERATION
ECU receives the data (such as ABS controller signal, wheel speed sensor signal) via the CAN bus lines.
If it cannot receive such data, it interrupts the system.
DOIMC023R11269
DOIMC023R11264 DOIMC023R11265
DOIMC023R11266 DOIMC023R11267
DOIMC023R11244 DOIMC023R11246
DOIMC023R11230 DOIMC023R11248
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Increased clamping level 0
2. Substitute detection func-
CAN wheel speed tion of blocked and spin- 1. Wheel speed sensor defective
U1016 2. Sensor wiring problem
sensor — front left ning wheels
3. Substitute front left wheel
speed
DOIMC023R11222
OPERATION
ECU receives the data (such as ABS controller signal, wheel speed sensor signal) via the CAN bus lines.
If it cannot receive such data, it interrupts the system.
DOIMC023R11269
DOIMC023R11264 DOIMC023R11265
DOIMC023R11266 DOIMC023R11267
DOIMC023R11244 DOIMC023R11246
DOIMC023R11230 DOIMC023R11248
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Increased clamping level 0
2. Substitute detection func-
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
OPERATION
ECU receives the data (such as ABS controller signal, wheel speed sensor signal) via the CAN bus lines.
If it cannot receive such data, it interrupts the system.
DOIMC023R11270
DOIMC023R11264 DOIMC023R11265
DOIMC023R11244 DOIMC023R11246
DOIMC023R11230 DOIMC023R11248
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Increased clamping level 0
2. Substitute detection func-
CAN wheel speed tion of blocked and spin- 1. Wheel speed sensor defective
U1018 2. Sensor wiring problem
sensor — rear left ning wheels
3. Substitute rear left wheel
speed
DOIMC023R11222
OPERATION
ECU receives the data (such as ABS controller signal, wheel speed sensor signal) via the CAN bus lines.
If it cannot receive such data, it interrupts the system.
DOIMC023R11270
DOIMC023R11264 DOIMC023R11265
DOIMC023R11244 DOIMC023R11246
DOIMC023R11230 DOIMC023R11248
TROUBLESHOOTING PROCEDURE
Fault code PADT–II display Reaction from TCU Probable cause
1. Increased clamping level 0
2. Substitute detection func-
CAN wheel speed
tion of blocked and spin- 1. Wheel speed sensor defective
U1019 sensor — rear 2. Sensor wiring problem
ning wheels
right
3. Substitute rear right wheel
speed
DOIMC023R11222
DOIMC023R11237
DIAGNOSIS PROCEDURE
DOIMC023R11250
DOIMC023R11252
DIAGNOSIS PROCEDURE
DOIMC023R11259
DIAGNOSIS PROCEDURE
DOIMC023R11261
DOIMC023R11231
DIAGNOSIS PROCEDURE
DOIMC023R11262
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
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
TERMINAL VOLTAGE
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 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
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
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
90 EDS2 Pin 8 and pin 90 2.5 V ± 0.5 V 5.7 Ω
switch: ON
Ignition
91 EDS1 Pin 8 and pin 91 2.5 V ± 0.5 V 5.7 Ω
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
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)
Pin no Signal
15 Drive mode sensor C (DMS_C)
16 Drive mode sensor D (DMS_D)
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-
7 Measure between pin 1 and pin 2 5.2 Ω
or (EDS2)
Clutch pressure regulator
5 Measure between pin 1 and pin 4 5.2 Ω
(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.
DOIMC023R11145
VIEW LOCATION
DOIMC023R11146 DOIMC023R11147
DOIMC023R11148 DOIMC023R11149
DOIMC023R11151 DOIMC023R11150
DOIMC023R11152 DOIMC023R11153
DOIMC023R11154 DOIMC023R11155
DOIMC023R11060
DOIMC023R11172
DOIMC023R11159
DOIMC023R11160
DOIMC023R11057
DOIMC023R11055
DOIMC023R11066
DOIMC023R11057
DOIMC023R11058
DOIMC023R11063
DOIMC023R11064
DOIMC023R11065
DOIMC023R11066
DOIMC023R11059
DOIMC023R11060
DOIMC032L08012
DOIMC023R11061
DOIMC023R11062
DOIMC023R11061
DOIMC023R11056
DOIMC032L08013
DOIMC023R11120
DOIMC023R11067
DOIMC023R11068
DOIMC023R11067
DOIMC023R11068
DOIMC023R11067
DOIMC023R11066
DOIMC023R11060
DOIMC023R11061
DOIMC023R11061
DOIMC023R11039
DOIMC023R11040
DOIMC023R11041
DOIMC023R11042
DOIMC032L08013
DOIMC023R11120
DOIMC023R11045
DOIMC023R11046
DOIMC023R11047
DOIMC023R11048
DOIMC023R11049
DOIMC023R11045
DOIMC023R11050
DOIMC023R11051
DOIMC023R11052
DOIMC023R11053
DOIMC023R11054
DOIMC023R11052
DOIMC023R11080
DOIMC023R11081
DOIMC023R11082
DOIMC023R11083
DOIMC023R11083
DOIMC023R11082
CAUTION
Torque the bolts as sequence as shown in
the illustration.
4. Install the primary cover (Detail procedure
for removal and installation of primary cover
refer to 23/216 ).
DOIMC023R11084
DOIMC023R11085
DOIMC023R11086
DOIMC023R11087
DOIMC023R11088
DOIMC023R11089
DOIMC023R11090
DOIMC023R11091
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 ).
DOIMC023R11120
DOIMC023R11092
DOIMC023R11093
DOIMC023R11094
DOIMC023R11095
DOIMC023R11096
DOIMC023R11097
CAUTION
Torque the bolts as sequence as shown in
the illustration.
5. Fill transmission oil according instruction,
(Detail procedure for fill and check transmis-
sion oil refer to 23/206 ).
DOIMC023R11098
DOIMC023R11101
DOIMC023R11102
DOIMC023R11103
DOIMC023R11104
DOIMC023R11105
DOIMC023R11103
DOIMC023R11106
DOIMC023R11107
DOIMC023R11107
DOIMC023R11108
DOIMC023R11109
CAUTION
Torque the bolts as sequence as shown in
the illustration.
5. Install the drive mode sensor, (Detail proced-
ure for remove the drive mode sensor refer
to 23/228 ).
6. Install the oil pan and oil filter, (Detail pro-
cedure for install the oil pan and oil filter
refer to 23/225 ).
DOIMC023R11156
DOIMC023R11157
DOIMC023R11158
DOIMC023R11156
DOIMC023R11112
DOIMC023R11113
DOIMC023R11113
DOIMC023R11115
DOIMC023R11116
DOIMC023R11117
DOINT23CR11037
DOIMC023R11118
DOIMC023R11174
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
DOIMC023R11176
DOIMC023R11183
DOIMC023R11184
DOIMC023R11177
DOIMC023R11178
DOIMC023R11179
DOIMC023R11180
ECU REMOVAL
CAUTION
Before remove the ECU wiring harness connect-
ors, ensure disconnect the battery terminal first.
1. Use the small screw driver to push the ECU
connector lock.
DOIMC023R11175
DOIMC023R11176
DOIMC023R11183
DOIMC023R11184
DOIMC023R11185
ECU INSTALLATION
DOIMC023R11186
Reverse order the removal procedure to install
back the ECU.
CAUTION
After install the ECU , ensure the connectors fits
in firmly on TCU or ECU pin.
DOIMC023R11275
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 .
DOIMC023R11074
DOIMC023R11276
DOIMC023R11277
DOIMC023R11278
DOIMC023R11279
DOIMC023R11281
DOIMC023R11068
DOIMC023R11011
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)
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.
DOIMC023R11001
DOIMC023R11002
DOIMC023R11003
DOIMC023R11004
DOIMC023R11005
DOIMC023R11006
DOIMC023R11007
DOIMC023R11008
DOIMC023R11009
DOIMC023R11001
DOIMC023R11002
DOIMC023R11036
DOIMC023R11037
DOIMC023R11128
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,
T2 : 5.7 kgm (57 Nm, 41.23 ft.lbs) ± 0.7 kgm (7 Nm, 2.17 ft.lbs)
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)
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 of the removal service procedure for the
Air-cleaner, refer to GROUP 015 – Air-cleaner
(PUB. NO. RDWE-08MA010).
DOIMC023R11014
DOIMC023R11015
DOIMC023R11016
DOIMC023R11017
DOIMC032L08012
DOIMC023R11120
DOIMC023R11039
DOIMC023R11026
DOIMC023R11027
DOIMC023R11028
DOIMC023R11018
DOIMC023R11019
DOIMC023R11020
DOIMC023R11021
DOIMC023R11022
DOIMC023R11023
DOIMC023R11024
DOIMC023R11013
DOIMC023R11029
DOIMC023R11030
DOIMC023R11031
DOIMC023R11070
DOIMC023R11032
DOIMC023R11033
AIR-CLEANER INSTALLATION
NOTE:
Detail of installation service procedure for the
Air-cleaner, refer to GROUP 015 – Air-cleaner
(PUB. NO. RDWE-08MA010).
NOTE
26 FRONT AXLE
SPECIFICATIONS ....................................................................... 26/2
SERVICE SPECIFICATIONS .......................................................... 26/2
GENERAL SPECIFICATIONS ........................................................ 26/2
LUBRICANTS ......................................................................... 26/2
SPECIFICATIONS WCH026SPECS11001
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)
GENERAL SPECIFICATIONS
Items Specifications
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
Tool Number Name Use
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
DOIIC026R9016
DOIMC026R11018
DOIMC026R11017
DOIMC023R11039
DOIMC022R11036
DOIMC023R11043
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.
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
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.
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
DOIMC026R11001
DOIMC026R11016
DOIMC026R11008
DOIMC026R11009
DOIMC026R11002
DOIMC026R11003
CAUTION
(1) The drive shaft joint uses special grease.
Do not mix old and new or different
DOIMC026R11010 types of grease.
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.
DOIMC026R11011
DOIMC026R11005
DOIMC026R11016
DOIMC026R11014
DOIMC026R11015
DOIMC026R11006
DOIMC026R11007
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
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 : 5.7 kgm (57 Nm, 41.23 ft.lbs) ± 0.7 kgm (7 Nm, 5.06 ft.lbs)
T3* : 10.0 kgm (100 Nm, 72.33 ft.lbs) ± 1.0 kgm (10 Nm, 7.23 ft.lbs)
DOIMC032R11011
DOIMC032R11015
DOIMC032R11016
DOIMC032R11012
DOIMC032R11013
DOIMC032R11014
DOIMC032R11010
DOIMC032R11001
Non-reusable parts
Pre-removal and post-installation operation
• 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)
T2 : 5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.5 kgm (5 Nm, 3.62 ft.lbs)
T3 : 3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.3 kgm (3 Nm, 2.17 ft.lbs)
DOIMC032R11002
CVT Transmission:
1. Remove the insulator mounting bolt.
DOIMC032R11003
DOIMC032R11004
DOIMC032R11005
Manual transmission:
1. Remove the insulator mounting bolt.
DOIMC032R11006
DOIMC022R11029
DOIMC032R11007
DOIMC032R11008
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)
T2 : 5.7 kgm (57 Nm, 41.23 ft.lbs) ± 0.7 kgm (7 Nm, 5.06 ft.lbs)
T3 : 5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.5 kgm (5 Nm, 3.62 ft.lbs)
NOTE
NOTE
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)
SPECIFICATIONS
Items Standard value / Spec Limit
Wheel speed sensor model Pasline —
TOOLS
Tool Number Name Use
Vehicle communication
EZT0047 For vehicle diagnosis
interface (VCI)
DOIMC35BR11039
DOIMC35BR11042
DOIMC35BR11041
DOIMC35BR11046
DOIMC35BR11045
DOIMC35BR11040
DOIMC35BR11043
DOIMC35BR11044
DOIMC35BR11047
TROUBLESHOOTING WCH35BSHOOT10001
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.
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-
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.
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
Get an understanding of the problem diagnosis content and check according to the inspection dia-
gnosis chart.
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
DOIMC35BR11029
DOIMC35BR11023
DOIMC35BR11028
DOIMC35BR11022
DOIMC35BR11026
DOIMC35BR11020
DOIMC35CR11022
DOIMC35CR11009
DOIMC35CR11010
DOIMC35CR11014
DOIMC35BR11025
DOIMC35BR11019
DOIMC35BR11036
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
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 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
DOIMC35BR11031
DOIMC35BR11002
DOIMC35BR11032
DOIMC35BR11037
DOIMC35BR11033
DOIMC35BR11003
DOIMC35BR10003
DOIMC35BR10003
DOIMC35BR11035
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.
DOIMC35BR11013
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-
• pin terminal no.4 (A-41) ECU
lyzer to
A) (+) terminal of the ana-
• pin terminal no.17 (A-41) ECU
Rear RH Wheel speed lyzer to
sensor B) (-) terminal of the ana-
• pin terminal no.29 (A-41) ECU
lyzer to
A) (+) terminal of the ana-
• pin terminal no.31 (A-41) ECU
Rear LH Wheel speed lyzer to
sensor B) (-) terminal of the ana-
• pin terminal no.18 (A-41) ECU
lyzer to
Standard Wave Pattern
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.
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.
2. Turn the ignition switch ON.
3. Observe the voltage signal using the analyzer.
NOTE
Recommended analyzer setting;
• Y-axis: 5V
• X-axis: 100ms
Standard Wave Pattern
DOIMC35BR11018
1. Check the wave generated by the analyzer is the same as the standard wave form.
2. Check that the voltage value;
DOIMC35BR10009
Pre-removal Operation
• Brake fluid draining.
Post-installation Operation
• 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
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)
Symbol Description
A Push Lock connector
B Pull – up lever
DOIMC35BR11008
DOIMC35BR11009
ON-VEHICLE SERVICE
REMOVAL SERVICE POINT
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
Symbol Description
A Front sensor
B Front rotor
DOIMC35BR10004 C 1.0 ± 0.1 mm (0.039 ± 0.004 in)
E ABS front sensor
Symbol Description
A Rear sensor
B Rear rotor
C 1.0 ± 0.1 mm (0.039 ± 0.004 in)
F ABS rear sensor
DOIMC35BR10005
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)
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).
Symbol Description
A Pedal down
B Pedal up
C Lock nut
DOIIC35AR9006
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.
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-
DOIIC35AR9018
NOTE
AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCED- 52B/94
U R E ......................................................................................
GENERAL INFORMATION .......................................................... 52B/94
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
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
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
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).
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-ECU Pin
Destination of Harness Corrective Action
No.
5 SRS-ECU pin no 5 ⇒ SRS-ECU pin no 6
6 SRS-ECU pin no 6 ⇒ SRS-ECU pin no 5
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
25 Instrument panel (RH) wiring harness ⇒
PCB box fuse no. 12 (10A)
33 SRS-ECU pin no 33 ⇒ SRS-ECU pin no 34
34 SRS-ECU pin no 34 ⇒ SRS-ECU pin no 33
46 Instrument panel (RH) wiring harness ⇒
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 module- if 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.
DOIKC52BR03134
DOIIC52BR9003
Vehicle communication
EZT0047 For vehicle diagnosis
interface (VCI)
DOIMC35BR11039
DOIMC35BR11042
DOIMC35BR11041
DOIMC35BR11046
DOIMC35BR11045
DOIMC35BR11040
DOIMC35BR11043
DOIMC35BR11044
DOIMC35BR11047
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”.
DOIMC52BR11003
TROUBLESHOOTING WCH52BTSHOT11001
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
DOIMC52BR10001
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
• Short in driver's airbag module (squib)
B1022 Driver front airbag short circuit to battery
harness leading to the power supply
• Short in driver's airbag module (squib)
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
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
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.
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
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
for leakage to ground.
OK: No continuity
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
check for leakage to ground.
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
check for leakage to ground.
OK: No continuity
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
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
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
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
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
Repair Instructions Condition Next State
Replace the Airbag Control Unit (Refer to 52B/77 ). OK Stop
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
Symbol Description
A Front airbag module
DOIMC52BR10002
INSPECTION PROCEDURE
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
CONTINUITY INSPECTION
Instructions Condition Next State
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.
OK go to 3
DOIMC52BR10014
Check continuity between E–09 pin no. 4 and E–09 pin no. 11 to check
for leakage to ground.
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
check for leakage to ground.
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
• Disconnect C–14 connector.
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
harness. Repair the damaged line or if necessary, replace the harness.
OK go to 3
DOIMC52BR10010
• Reconnect all disconnected passenger front airbag connectors.
• Reconnect the negative (-) battery terminal.
• Switch the ignition ON.
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
• Disconnect C–14 connector.
Check leakage to plus between C–14 pin no. 14 and E–09 pin no. 11.
OK: Voltage reading OV
3 NG Go to 4
OK go to 7
DOIMC52BR10012
Check leakage to plus between E–09 pin no. 3 and E–09 pin no. 11.
OK: Voltage reading OV
4 NG Go to 6
OK go to 5
DOIMC52BR10013
• Disconnect C–14 connector.
Check leakage to plus between C–14 pin no. 13 and E–09 pin no. 11.
OK: Voltage reading OV
OK Stop
DOIKC35BR03090
A wiring fault (leakage to plus line) is present at the respective floor
harness. Repair the damaged line or if necessary, replace the harness.
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
harness. Repair the damaged line or if necessary, replace the harness.
CAUTION
The battery negative (-) terminal MUST be disconnected after leakage
to plus inspection and before the repair work is conducted.
7 Replace Air Bag Control Unit (Refer to 52B/77 ). OK Stop
FAULT CODE B1028: PASSENGER FRONT AIRBAG SHORT CIRCUIT
Repair Instructions Condition Next State
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.
OK Stop
DOIKC35BR03090
Short circuit is present at the dash harness. Repair the damaged line
or if necessary, replace the harness.
5 Replace the Airbag Control Unit (Refer to 52B/77 ). OK Stop
FAULT CODE B029: PASSENGER FRONT AIRBAG OPEN CIRCUIT
Repair Instructions Condition Next State
1 Replace the Airbag Control Unit (Refer to 52B/77 ). OK Stop
REMOVAL SERVICE POINT
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 passenger
front airbag module and the floor har-
ness 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.
Symbol Description
A Front airbag module
WARNING
• Never connect battery or turn the ignition
switch ON while removing or installing the
airbag module.
DOIJC52BR01024
• Never use ohmmeter or other current-carry-
ing devices to test the airbag module.
DOIMC52BR07039
POST-INSTALLATION
PASSENGER FRONT AIRBAG
CONNECT / RECONNECT THE FOLLOWING (Upon
completion of the repair works for system
check):
1. Airbag simulator to all the harness connect-
ors for airbag. (Driver, passenger and both
side airbags).
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
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.
1. Check hard cover for dents, cracks or deform-
ities.
2. Check the air bag module for denting,
cracking 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.
DOIMC52BR07062
1
OK go to 2
DOIGC13AR03129
Check E-16 and E-09 connectors for proper condition and
mating.
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
After checking that continuity in the harnesses are ok or recti-
4 OK STOP
fied, proceed to Fault Code Inspection.
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.
4 Replace Airbag Control Unit (Refer to 52B/77 ). OK STOP
1
OK go to 2
DOIMC52BR07056
• Reconnect all driver pretensioner connectors.
• Reconnect the negative (-) battery terminal.
• Switch the ignition ON.
Check connector E-09 between pin no. 9 and pin no. 11 for leakage
to plus checking.
OK : 0 voltage
NG go to 3
2
OK go to 4
DOIMC52BR07057
Check connector E-09 between pin no. 8 and pin no. 11 for leakage
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.
4 Replace Airbag Control Unit (Refer to 52B/77 ). OK STOP
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
line or if necessary, replace the harness.
3 Replace the Airbag Control Unit (Refer to 52B/77 ). OK STOP
FAULT CODE B1034: DRIVER PRE TENSIONER OPEN CIRCUIT
Repair Instructions Condition Next State
1 Replace the Airbag Control Unit (Refer to 52B/77 ). OK STOP
REMOVAL SERVICE POINT
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
– 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.
Symbol Description
A Front airbag module
DOIJC52BR04013
WARNING
– Never connect battery or turn the ignition
switch ON while removing or installing the
airbag module.
– Never use ohm meter or other current-carrying
devices to test the airbag module.
DOIMC52BR07039
POST-INSTALLATION
DRIVER PRE TENSIONER
CONNECT / RECONNECT THE FOLLOWING (Upon
completion of the repair works for system
check):
• Airbag simulator to all the harness connect-
ors 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
Airbag simulator and sub
A
harness
Body harness connector for
B
side airbag/pre-tensioner
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
Never attempt to measure the circuit resistance
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.
1. Check hard cover for dents, cracks or deform-
ities.
2. Check the air bag module for denting,
cracking 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.
Symbol Description
A Front airbag module
DOIMC52BR10003
INSPECTION PROCEDURE
Step Instruction Condition Next Step
PADT-II Diagnose Code NO Go to 2
• Reconnect floor harness connector for SRS-ECU
• Reconnect the (-) battery terminal
1
• Using PADT-II, erase fault code
• OK : Fault code deleted
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
CONTINUITY INSPECTION
Instruction Condition Next State
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
DOIMC52BR07055
Check for continuity between E-09 pin no. 7 and E-19 pin no.
1.
OK: Continuity
After checking that continuity in the harnesses are ok or recti-
4 OK STOP
fied, proceed to Fault Code Inspection.
OK go to 2
DOIMC52BR10017
• Reconnect all passenger pre tensioner connectors.
• Reconnect the negative (-) battery terminal.
• Switch the ignition ON.
Check leakage to plus between E–09 pin no. 6 and E–09 pin no. 11.
OK: Voltage reading OV
2 NG Go to 3
OK go to 4
DOIMC52BR10018
Check leakage to plus between E–09 pin no. 5 and E–09 pin no. 11.
OK: Voltage reading OV
3
OK Stop
DOIKC35BR03090
A wiring fault (leakage to plus line) is present at the respective floor
harness. Repair the damaged line or if necessary, replace the harness.
CAUTION
The battery negative (-) terminal MUST be disconnected after leakage
to plus inspection and before the repair work is conducted.
4
OK Stop
Replace Airbag Control Unit (Refer to 52B/77 ).
FAULT CODE B1037: PASSENGER PRE TENSIONER SHORT CIRCUIT TO BATT
Repair Instructions Condition Next State
1 NG go to 3
OK go to 2
DOIMC52BR10017
Check continuity between E–09 pin no. 6 and E–09 pin no. 11 to check
for leakage to ground.
OK: No continuity
2 NG Go to 3
OK go to 4
DOIMC52BR10018
Check continuity between E–09 pin no. 5 and E–09 pin no. 11 to check
for leakage to ground.
OK: No continuity
3
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.
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
or if necessary, replace the harness.
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
1 Replace the Airbag Control Unit (Refer to 52B/77 ). OK Stop
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 passenger
front airbag module and the floor har-
ness 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 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
• Never connect battery or turn the ignition
switch ON while removing or installing the
airbag module.
• Never use ohm meter or other current-carry-
ing devices to test the airbag module.
DOIMC52BR07039
POST-INSTALLATION
PASSENGER PRETENSIONER
CONNECT / RECONNECT THE FOLLOWING (Upon
completion of the repair works for system
check):
1. Airbag simulator to all the harness connect-
ors for airbag. (Driver, passenger and both
side airbags).
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
check system on combination meter SRS in-
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 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
Never attempt to measure the circuit resist-
ance of the airbag module (squib) even if
you are using the specified tester. If the cir-
cuit resistance is measured with a tester,
airbag accident deployment will result in
serious personal injury.
2. Check hard cover for dents, cracks or deform-
ities.
3. Check the airbag module for denting, crack-
ing or deformation.
4. Check hooks and connectors for damage,
terminals for deformities, and harness for
binds.
5. Check air inflator case for dents, cracks or
deformities.
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
• OK : No continuity
4
OK go to 8
DOIMC52BR07068
• Check for continuity between D-06 pin no. 6 and E-09 pin no.
11
• OK : No continuity
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.
• OK : No continuity
• 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).
• Delete fault code
• A wiring fault (leakage to ground) is present at the wire con-
necting D-06 and C-13 connectors.
7 • Repair the damaged line or if necessary, replace fuse no. 16 OK STOP
(in instrument panel fuse box).
• Delete fault code
• A wiring fault (leakage to ground) is present at the wire con-
necting D-06.
8 • Repair the damaged line or if necessary, replace fuse no. 16 OK STOP
(in instrument panel fuse box).
• Delete fault code
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
DOIMC015R07017
Symbol Description
A Battery cable
B Insulating tape
C Battery
2. Disconnect the following connectors :
Disconnect safety connector
• Squib connector for driver airbag.
• Dash harness connector for passenger
front airbag module and the floor har-
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
A Front airbag module
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
• 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
CONNECT / RECONNECT THE FOLLOWING (Upon
completion of the repair works for system
check):
• Airbag simulator to all the harness connect-
ors for airbag. (Driver, passenger and both
side airbags).
• Airbag simulator to both pre-tensioner seat
belts.
• Connector to Air Bag Control Unit.
• Battery (-) terminal.
Symbol Description
A Airbag simulator and sub
harness
B Body harness connector for
side airbag/pre-tensioner
C Airbag control unit (ECU)
D Connector side airbag
E Lock lever
DOIJC52BR04126
Symbol Description
A Ignition key to “ON” posi-
tion.
DOIMC52BR07010
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 )
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
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.
DOIMC52BR07002
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.
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 )
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 )
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.
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
(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.
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.
DOIMC52BR07005
Symbol Description
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
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.
Pre-removal Operation
• 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)
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.
Symbol Description
A Bolt
B Earthing harness
C Air Bag Control Unit
DOIMC52BR07007
Symbol Description
A Air Bag Control Unit
B Stopper lock
DOIHC52BR06006 C Lock lever
DOIMC52BR07003
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.
Pre-removal Operation
• 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
• Pre-installation inspection
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
DOIMC015R07017
Symbol Description
A Battery cable
B Insulating tape
C Battery
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
INSPECTION
CLOCK SPRING
Disconnect body harness from clock spring
socket.
INSTALLATION SERVICE POINT
PRE-INSTALLATION INSPECTION
1. When installing the new air bag module and
clock spring, refer to INSPECTION section
(refer on next page).
DOIMC52BR07004
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
Wait at least 5 minutes after disconnecting
the battery cable before doing any further
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
supplier for destruction. This should not be
handled by unauthorized personal.
CAUTION
Never attempt to measure the circuit resist-
ance of the air bag module (Squib) even if
DOIJC52BR04013
you are using the specified tester. If the cir-
cuit resistance is measure with a tester, acci-
Symbol Description
A Pad cover
1. Check pad cover for dents, cracks or deform-
ities.
2. Check the air bag module for denting,
cracking or deformation.
3. Check hooks and connector for damage,
terminals for deformities, and harness for
binds.
4. Check air inflator case for dents, cracks or
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.
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.
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
1. If any improper part is found during the fol-
lowing inspection, replace the air bag mod-
ule with a new one. Dispose the old accord-
ing to the specified procedure.
CAUTION
Never attempt to measure the circuit resist-
ance of the air bag modules (squib) even if
you are using the specified tester. If the cir-
cuit resistance is measured with a tester,
accidental air bags deployment will result in
serious personal injury.
2. Check cover for dents, cracks or deformation.
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
DOIMC52BR10021
DOIMC015R07017
Symbol Description
A Positive (+) battery terminal
B Negative (-) battery terminal
covered with insulating tape
C Battery
DOIMC52BR10033
DOIMC52BR10039
Symbol Description
A Lock lever
B Harness connector
C Flat-tip screwdriver
DOIMC52BR10040
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
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
supplier for destruction. This should not be
handled by unauthorized personal.
CAUTION
Never attempt to measure the circuit resist-
ance of the air bag modules (squib) even if
DOINC52BR09038
you are using the specified tester. If the cir-
cuit resistance is measured with a tester,
accidental air bags deployment will result in
serious personal injury.
2. Check cover for dents, cracks or deformation.
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
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.
DOIMC52BR07008
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.
Pre-removal and Post-installation Operation
• 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
• Pre-installation inspection
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
PRE-INSTALLATION INSPECTION
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
Never attempt to measure the circuit resistance
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.
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.
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
Symbol Description
A Clock spring connector
B SRS air bag adapter harness
C Deployment wires
DOIMC52BR07017
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.
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-
ness and cover the connections with insula-
tion tape. The other ends of the two wires
should be connected to each other (short
circuited), to prevent sudden unexpected
deployment of the seat belt pre-tensioner.
Symbol Description
A SRS air bag adapter harness
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
A SRS air bag adapter harness
B Seat belt pre-tensioner
C Deployment wires
DOIMC52BR07020
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 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.
Symbol Description
A SRS air bag adapter harness
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.
Symbol Description
A Tyres without wheels
B Deployment wires
DOIMC52BR07024
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.
Symbol Description
A SRS air bag adapter harness
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
Symbol Description
A Tyres without wheels
B Deployment wires
DOIMC52BR07024
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 )
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
54 CHASSIS ELECTRICAL
COMBINATION METER ............................................................... 54/2
SERVICE SPECIFICATIONS .......................................................... 54/2
SEALANT ............................................................................. 54/2
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
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
Standard value:
Point F +5Ω
(highest) 26 Ω
–5Ω
Point E +5Ω
(lowest) 285 Ω
–5Ω
Symbol Description
1 Fuel gauge (Meter)
2 Fuel pump (+)
3 —
4 Fuel pump (–)
5 Fuel gauge (Ground)
DOIMC054R11011
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
SPECIFICATIONS WCH055SPECS11001
GENERAL SPECIFICATIONS
Items 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)
DOIMC055R11002
Symbol Description
A Brake oil reservoir
B Brake pipeline
DOIMC055R08415
DOIMC055R08416
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.
INSTALLATION SERVICE POINT
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.
Compressor oil:
SANDEN SP 10
Items Quantity
Suction hose 30 cm³ (1.83 cu.in)
COMPRESSOR WCH055SASSY11002
DOIMC055R11001
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.)
ABS-ECU...................................................... 35B/38