Preve Suprima Workshop Manual

WORKSHOP MANUAL
INSPECTION & MAINTENANCE
CR FT
RA
D
Model YR 2012
English Edition RDCE-1200CR050-00
Destination: MHR
February 2012 Printed in Malaysia
Copyright ©
Perusahaan Otomobil
Nasional Sdn. Bhd.
(Company No.: 100995-U)
FT
RA
D
Printed in Malaysia 13 February 2012 Eng

WORKSHOP MANUAL ALL
Group Index /I
00 GENERAL ................................................................................... 00/1 - 00/10

1 PRE-DELIVERY INSPECTION ............................................................. 1/1 - 1/22
2 PERIODIC INSPECTION AND MAINTENANCE .................................... 2/1 - 2/19
FT
RA
D
All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.

ALL WORKSHOP MANUAL
/ II Group Index
NOTE
FT
RA
D

GENERAL 00
Content /1
00 GENERAL
FOREWORD ............................................................................ 00/2
HOW TO USE THIS MANUAL ....................................................... 00/3

EXPLANATION OF MANUAL CONTENTS ........................................ 00/3
ABBREVIATIONS ..................................................................... 00/3
MODEL ................................................................................ 00/4
SEDAN ................................................................................ 00/4
PRECAUTIONS BEFORE SERVICE ................................................... 00/4
FT
PROTECTING THE VEHICLE ........................................................ 00/4
DOING SERVICE WORK IN GROUPS OF TWO OR MORE MECHANICS .... 00/4
REMOVAL AND DISASSEMBLY ................................................... 00/5
SPECIAL TOOLS ...................................................................... 00/5
PARTS TO BE REPLACED ........................................................... 00/6
PARTS .................................................................................. 00/6
TUBES AND OTHER RUBBER PARTS ............................................. 00/6
LUBRICANTS ......................................................................... 00/6
RA
BRAKE FLUID ......................................................................... 00/7
SERVICING THE ELECTRICAL SYSTEM ........................................... 00/7
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
IN ORDER TO PREVENT VEHICLES FROM FIRE ................................. 00/7
ENGINE OILS ......................................................................... 00/7
Health Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
Recommended Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
SUPPORT LOCATIONS FOR LIFTING AND JACKING ............................. 00/8

H-BAR LIFT ........................................................................... 00/9
MAKING WOODEN ATTACHMENTS ............................................. 00/10
D

00 GENERAL
/2 FOREWORD
FOREWORD PDI000FWORD11003
This Inspection and Maintenance Manual explains the main points necessary for inspection and
maintenance of Proton vehicles, combining Pre-Delivery Inspection and Periodic Inspection in one
volume. It is intended to contain enough information to allow the user to conduct work quickly and
with precision .
For checking procedures, specifications, tightening torques, etc., there may be instances in which
reference to the Workshop Manual is necessary. If so, refer to the Workshop Manual applicable to
that model.
All information, illustrations and product descriptions contained in this manual are current as of time
FT
of publication. We, however, reserve the right to make changes at any time without prior notice for
obligation.
RA
D

GENERAL 00
HOW TO USE THIS MANUAL /3
HOW TO USE THIS MANUAL PDI000GINFO11001
EXPLANATION OF MANUAL CONTENTS
FT
RA
D
DOIIP000R9001
Symbol Description
A Indicates the group title
B Indicates the section title
C Indicates the group number
D Indicates the page number
Indicates the inspection to be made. The number preceding the indication of the in-
E spection to be made is the same number as that used preceding in the periodic inspec-
tion and maintenance schedule.
F Indicates the Maintenance interval
Indicates the maintenance operation code.
G I : Inspection
R : Replace or change
ABBREVIATIONS
CO : Carbon Monoxide
EGR : Exhaust Gas Recirculation
M.P.I : Multi Point Injection
CFE : Charged Fuel Efficient

00 GENERAL
/4 PRECAUTIONS BEFORE SERVICE
P.A.D.T : Proton Advance Diagnostic Tool

SOHC : Single Overhead Camshaft
DOHC : Double Overhead Camshaft
FWD : Front Wheel Drive Vehicles
M / T : Manual Transmission
A / T : Automatic Transmission
CVT : Continuously Variable Transmission
ISC : Idling Speed Control
FT
SRS : Supplemental Restraint System
A.B.S : Anti-skid Brake System
TC : Traction Control
MODEL
SEDAN
Fuel Supply Sys-
Model Code Engine Model Transmission Model
RA
tem
CR6SNBYRMA0 <5MTT200A>
CR6STBYRMA0 CVT2
CR S4PH
CR6SNJYRMA0 <5MTT200A> MPI
MHR
CR6STJYRMA0 CVT2
CR6SDHARMA0 S4PH-CFE CVT3
PRECAUTIONS BEFORE SERVICE

PDI000BSERV11001
D
PROTECTING THE VEHICLE

If there is a likelihood of damaging interior or
exterior parts during service operations, protect
them with suitable covers (such as Seat covers,
Fender covers, etc.).
DOIIP000R9015
DOING SERVICE WORK IN GROUPS OF

TWO OR MORE MECHANICS
If the service work is to be done by two or more
mechanics working together, all the mechanics
involved should take safety into consideration
while they work.
DOIIP000R9016

GENERAL 00
PRECAUTIONS BEFORE SERVICE /5
REMOVAL AND DISASSEMBLY

When checking a malfunction, find the cause of
the problem. If it is determined that removal
and/or disassembly is necessary, perform the
work by following the procedures contained in
this Manual.
FT
DOIIP000R9017
If punch marks or marks or mating marks are

made to avoid error in assembly and facilitate
the assembly work, be sure to make them in
locations which will have no detrimental effect
on performance and/or appearances.
RA
If an area having many parts, similar parts, and/or
parts which are symmetrical right and left is dis-
assembled, be sure to arrange the parts so that
they do not become mixed during the assembly
process.
1. Arrange the parts removed in the proper or-
der.
DOIIP000R9018 2. Determine which parts are to be reused and
which are to be replaced.
3. If bolts, nuts, etc., are to be replaced, be sure
to use only the exact size specified.
D
SPECIAL TOOLS
If other tools are substituted for the special tools
to do service or repair work, there is the danger
that vehicle parts might be damaged, or the
technician might be injured; therefore, be sure
to use the special tool whenever doing any work
for which the use of one is specified.
DOIIP000R9019

00 GENERAL
/6 PRECAUTIONS BEFORE SERVICE
PARTS TO BE REPLACED
If any of the following parts are removed, they
must be replaced with new parts.
1. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packing
4. O-ring
5. Lock washers
6. Split pins
7. Self-locking nuts
FT
DOIIP000R9020
PARTS
When replacing parts, use PROTON genuine
parts.
RA
DOIIP000R01026
TUBES AND OTHER RUBBER PARTS

Be careful to avoid spilling any petrol, oil, etc.,
D
because if it adheres to any tubes or rubber parts,

they might be adversely affected.
DOIIP000R9022
LUBRICANTS
In accordance with the instruction in this Manual,
apply the specified lubricants in the specified
locations during assembly and installation.
DOIIP000R9023

GENERAL 00
PRECAUTIONS BEFORE SERVICE /7
BRAKE FLUID
Be careful to avoid spilling any brake fluid, be-
cause if it adheres to the vehicle body, the paint
coat might be discolored.
FT
DOIIP000R9024
SERVICING THE ELECTRICAL SYSTEM

1. When working on the electrical system, be
sure to avoid arbitrary changes to the elec-
trical devices or wiring as such can cause
electrical overloading and shorts, and fire.
RA
2. When servicing the electrical system, discon-
nect the negative cable terminal from the
battery.
CAUTION
Before connecting or disconnecting the
negative cable, be sure to turn off the igni-
DOIIP000R9025 tion switch and the lighting switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)
D
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Refer to Workshop Manual Chassis – Group 52B.
IN ORDER TO PREVENT VEHICLES FROM FIRE
“Improper installation of electrical or fuel related parts could cause a fire. In order to retain the high
quality and safety of the vehicle, it is important that any accessories that may be fitted or modifica-
tions/repairs that may be carried out which involve the electrical or fuel systems, MUST be carried out
in accordance with PROTON'S Information/Instructions”.
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 contaminants 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 oils, 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.

00 GENERAL
/8 SUPPORT LOCATIONS FOR LIFTING AND JACKING
• 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 footwear. 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, thinners or solvents for cleaning skin.
FT
• 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.
SUPPORT LOCATIONS FOR LIFTING AND JACKING PDI000SLIFT11001

RA
—
DOIJP000R04001 DOIJP000R04002
D
DOIIP000R9005 DOIIP000R9006 DOIIP000R9007
DOIIP000R9008 DOIIP000R9010
DOIIP000R9009
Label Description
A Garage jack

GENERAL 00
SUPPORT LOCATIONS FOR LIFTING AND JACKING /9
Label Description
B Axle stand
C Single-post lift
D Double-post lift
E H-bar lift
F Notch
H-BAR LIFT
If, when an H-bar lift (E) is used for lifting the
FT
vehicle, the metal attachment (G) included with
the H-bar lift (E) is used, there is the possibility
of damage to the suspension arms, etc, thus, the
following procedures should be followed for
lifting.
1. The vehicle should be placed on the H-bar
lift (E) in the same direction.
RA
DOIIP000R9011
2. Place the attachments (G) on the H-bar lift

(E) so that there is contact at designated
chassis location. Note that attachments (G)
are made according to the procedure de-
scribed afterward.
3. Refer to the respective model page for the
chassis support locations.
D
DOIIP000R9012

00 GENERAL
/ 10 SUPPORT LOCATIONS FOR LIFTING AND JACKING
MAKING WOODEN ATTACHMENTS

1. Prepare wooden blocks and nails (D) as
shown in the illustration
Item Size Quantity

Block (A) 90 x 95 x 2
1800 mm
(3.54 x 3.74
x 70.87 in)
Block (B) 60 x 100 x 4
FT
95 mm (2.36
x 3.94 x 3.74
in)
Block (C) 140 x 40 x 8
95 mm (5.51
x 1.57 x 3.74
in)
RA
Nails (D) 70 mm (2.76 as needed
in) or longer
CAUTION
The material used for the blocks must be
hard wood.
2. Make grooves of the dimensions shown in
the illustration in blocks (B) and (C) by using
DOIIP000R9013 a saw and chisel.
3. Use the nails to the nail blocks (B) and (C)
together so that block (B) sandwiched in
D
between; make four attachments such as

shown in the illustration.
4. Finished wooden attachment.
Symbol Description
(A) Movable according to chassis
width
DOIIP000R9014

PRE-DELIVERY INSPECTION 1
Content /1
1 PRE-DELIVERY INSPECTION
NOTES CONCERNING ENTRIES ..................................................... 1/4
TABLE OF PRE-DELIVERY INSPECTION ............................................ 1/4

INSPECTION PROCEDURE .......................................................... 1/5
First step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
Under Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
Under vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
Before Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
FT
Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
After Road Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/5
Final Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/6
PAINTWORK TERMS .................................................................. 1/6
FIRST STEP .............................................................................. 1/7
BODY .................................................................................... 1/7

RA
2. VEHICLE WASHING .............................................................. 1/7
3. EXTERIOR .......................................................................... 1/8
4. OPERATION OF DOOR LOCKING SYSTEMS AND DOOR HINGES ........ 1/8
5. OPERATION OF DOOR MIRRORS AND WINDOWS ........................ 1/9
FRONT LH/RH WINDOW GLASS RUNCHANNEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/10
UNDER HOOD ......................................................................... 1/11

6. ENGINE OIL LEVEL ............................................................... 1/11
7. BRAKE MASTER CYLINDER FLUID LEVEL .................................... 1/11
8. WASHER FLUID LEVEL ........................................................... 1/12
9. BATTERY CONDITION AND CONNECTIONS ................................. 1/12
D
10. POWER STEERING FLUID LEVEL ............................................. 1/12

11. ELECTRICAL WIRING ........................................................... 1/12
UNDER VEHICLE ....................................................................... 1/13

12. TYRE AND SPARE TYRE PRESSURES ......................................... 1/13
13. SUSPENSION SYSTEM .......................................................... 1/13
14. STEERING LINKAGE AND DRIVER SHAFT .................................. 1/14
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/14
Driver Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/14
15. UNDER BODY ................................................................... 1/14
Body Coating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/14
Check brake hoses and pipes for leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/15
BEFORE ROAD TEST .................................................................. 1/15

16. SEAT ADJUSTERS AND SEAT BACK LATCHES .............................. 1/15
17. INSTRUMENT PANEL CONTROLS ............................................ 1/16
18. METERS, GAUGES, WARNING LAMPS AND INDICATION LAMPS ...... 1/16
19. AIR CONDITIONING, VENTILATOR AND DEFROSTER SYSTEM ......... 1/16
Operation of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/16
20. WIPERS AND WASHERS ....................................................... 1/17
Front wiper and washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/17
21. OPERATION OF SERVICE BRAKE AND PARKING BRAKE ................ 1/17
22. CLUTCH OPERATION ........................................................... 1/18
23. OPERATION OF SEAT BELTS, SHOULDER BELTS AND RETRACTORS ... 1/18
ROAD TEST ............................................................................. 1/18

/2 Content
24. ENGINE PERFORMANCE AND EXHAUST GAS ............................. 1/18

25. TRANSMISSION IN ALL RANGES ............................................. 1/18
26. BRAKES ........................................................................... 1/19
27. STEERING CONTROL ........................................................... 1/19
28. VIBRATION AND RATTLES .................................................... 1/19
29. ELECTRICAL EQUIPMENT ..................................................... 1/20
AFTER ROAD TEST .................................................................... 1/20

30. VEHICLE DIAGNOSIS ........................................................... 1/20
31. RADIATOR COOLANT LEVEL ................................................. 1/20
FT
32. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER HOOD ... 1/21
33. MANUAL TRANSMISSION OIL LEVEL ....................................... 1/21
34. ENGINE, TRANSMISSION AND POWER STEERING UNITS ............... 1/21
35. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER VEHICLE . 1/21
FINAL STEP ............................................................................. 1/22

36. HEADLAMP AIMING ........................................................... 1/22
37. EQUIPMENT ..................................................................... 1/22
38. EXTERIOR AND INTERIOR ..................................................... 1/22
RA
39. OWNER'S INSTRUCTIONS ..................................................... 1/22
D

Content /3
NOTE
FT
RA
D

/4 NOTES CONCERNING ENTRIES
NOTES CONCERNING ENTRIES

PDI001NOTES11001
This section describes the details and the inspec-

tion methods employed for the pre-delivery in-
spection of vehicles.
The inspection should be conducted according
to the sequence described in the TABLE OF PRE-
DELIVERY INSPECTION (below).
Inspection methods are described following the
TABLE OF PRE-DELIVERY INSPECTION.
FT
NOTE
(1) The spaces for model, C/# (Chassis number),
E/# (engine number), aggregate distance
travelled in kilometres (miles), date of inspec-
tion, name of person conducting the inspec-
tion, and body colour must be completed
without fail.
(2) The spaces for place of inspection, and name
RA
of owner should be completed as required.
TABLE OF PRE-DELIVERY INSPECTION PDI001TABLE11001

D
DOIQP001R11002
PDI Inspection
Model
Chassis number
Engine number
Distance travelled Km (Miles)
Owner
Date of inspection
Place of inspection
Inspector
Body colour
Symbols to be used
Needs adjustment Needs retighten-
√ Good A T
ing

TABLE OF PRE-DELIVERY INSPECTION /5
Symbols to be used
Needs replenishment Needs replace-
C Needs cleaning L X
of lubricant, water, etc. ment or repair
INSPECTION PROCEDURE
First step
1. [..........] Connection of the dark current connector.
Body
2. [..........] Vehicle washing
FT
3. [..........] Exterior
4. [..........] Operation of door locking systems and door hinges
5. [..........] Operation of door mirrors and windows
Under Hood
6. [..........] Engine oil level
7. [..........] Brake master cylinder fluid level
8. [..........] Washer fluid level
RA
9. [..........] Battery condition and connections
10. [..........] Power steering fluid level
11. [..........] Electrical wiring
Under vehicle
12. [..........] Tyre and spare tyre pressures
13. [..........] Suspension system
14. [..........] Steering linkage and driver shaft
15. [..........] Under body
Before Road Test
D
16. [..........] Seat adjusters and seat back latches

17. [..........] Instrument panel controls
18. [..........] Meters, gauges, warning lamps and indication lamps
19. [..........] Air conditioning, ventilator and defroster systems
20. [..........] Wipers and washers
21. [..........] Operation of service brakes and parking brakes
22. [..........] Clutch operation
23. [..........] Operation of seat belts, shoulder belts and retractors
Road Test
24. [..........] Engine performance and exhaust gas
25. [..........] Transmission in all ranges
26. [..........] Brakes
27. [..........] Steering control
28. [..........] Vibration and rattles
29. [..........] Electrical equipment
After Road Test
30. [..........] Vehicle Diagnosis
31. [..........] Radiator coolant level
32. [..........] Hoses, fluid lines and connections located under hood
33. [..........] Manual transmission oil level
34. [..........] Engine, transmission and steering unit for leaks
35. [..........] Hoses, fluid lines and connections located under vehicle

/6 PAINTWORK TERMS
Final Step
36. [..........] Headlamp aiming
37. [..........] Equipment
38. [..........] Exterior and Interior
39. [..........] Owner's instructions
PAINTWORK TERMS PDI001PAINT11001
Term Definition Remarks

Blister A raised bubble in the paint (from
FT
the base or the undercoat) caused
by abnormal moisture. The bubble
may contain either water or air.
Change in The colour tone of the painted Including wrong colour, discoloration and decol-
tone surface is not uniform. ouration.
Contact mark A mark on the painted surface as a
result of contact by hands or cloth-
RA
ing at the time of paint application.
Crack A crack in the painted surface. Cracks may be either shallow or deep.
Dirt in paint- Rough surface resulting from for-
work eign material in the paint or from
dust deposited on wet paint during
painting or storage.
Filed or Deep scratches in sheet metal sur-
ground traces face, resulting improper use of
buffer or sander, are not com-
pletely covered, and are visible
D
through paint coating.

Orange peel The painted surface has the appear-
ance of an orange peel.
Peeling The paint flakes off (partly or over The peeling may be minor, medium, or major.
a wide area).
Pin holes Tiny holes in the painted surface.
Runs A visible trickle of dried paint on Either undercoat or top-coat.
the surface.
Scratches Scratches on the painted surface.
Shrink The painted surface “shrinks”,
causing wrinkles.
Smears Spots of soot or other material de- Including stains and water spots.
posited on the painted surface.
Spray mist The painted surface includes fine
particles or other paint.
Uneven lustre The lustre of the painted surface is
not uniform.
Uneven The metallic dispersion of the
metallic dis- painted surface is not uniform.
persion

FIRST STEP /7
Term Definition Remarks

Visibly incom- A part of the undercoating is vis-
plete topcoat- ible.
ing
FIRST STEP PDI001FIRST11001
DISCONNECTION OF BATTERY TERMINAL.

Disconnect the terminal connector to prevent
the battery from being run-down or short circuit.
FT
CAUTION
Disconnect the battery cable connector (A) and
avoid from touching battery terminal (B).
BODY PDI001BBODY11002
2. VEHICLE WASHING
DOIMP001R07026
RA
Step 1 Washing
Step 2 Removal of rust proofing agent
Step 3 Washing
Wash the body exterior with water to remove
dust. Then remove the paint protection wax with
wax remover and the rustproofing agent with
unleaded petrol respectively (for cars that are
applied with protective wax). Finally, wash the
body exterior carefully again. Take extra care
not to allow the wax removal to come in contact
D
with the front deck.

CAUTION
• When using the wax remover or unleaded
petrol, be careful to prevent the agent from
adhering to articles of rubber or plastic. If
this occurs, remove it immediately.
• To protect the wiper blade rubber, put a
cover on the wiper blade before starting the
dewaxing operation, and place the wiper
arm to the upright position. This will prevent
the wax remover from adhering to the wiper
blade rubber.

/8 BODY
3. EXTERIOR
1. Visually inspect the entire exterior.
• Paint condition
• Corrosion, scratches
• Bent edges, dented panels
2. Coated surfaces maintenance
Touch up minor paint chips and flaws.
NOTE
For terms of paintwork, refer to 1/6
FT
DOIQP001R11003
4. OPERATION OF DOOR LOCKING

SYSTEMS AND DOOR HINGES
1. Open each door to check the release mech-
anism and ease of operation.
RA
2. Close the door to check the latch and striker.
3. Open the door, operate the lock lever and
close the door to check the lock.
DOIQP001R11004
4. Partially close the door to check the open-

door detent.
D
5. Unlock each door with the key to check lock

operation.
6. Verify that all doors can be locked by the
lock buttons.
NOTE
Adjust and lubricate all latches, strikers,
hinges and locks as required.
7. Operate the lock lever at each front door
and verify that all doors can be locked and
unlocked simultaneously using the central
DOIQP001R11005
door locking system
8. Verify that the doors can be locked and un-
locked using the remote key.
9. Verify that the alarm system is working
properly

BODY /9
10. Open and close the trunk lid with sufficient

force to check the operation of release lever
and lock.
FT
DOIQP001R11006
11. Open and close the bonnet with sufficient

force to check operation of release lever and
safety lock.
NOTE
Adjust and lubricate all latches, strikers, hinges
and locks as required.
RA
DOIQP001R11007
12. Verify that the rear doors can't be opened

by the inner door handle when the child
protection knob at the end of the door is
D
shifted to the “LOCK” position with the in-

side lock knob at the UNLOCK position.
Symbol Description
1 Lock
2 Unlock
CAUTION
Set the lock to the “FREE” position on child
DOIQP001R11008
protection of both rear doors.
5. OPERATION OF DOOR MIRRORS AND

WINDOWS
1. Door mirrors
Check that it operate properly.
2. Door windows
Close and open all door windows to fully
closed position to check ease of operation.
Symbol Description
A Door mirrors switch
DOIQP001R11009

/ 10 BODY
3. Power windows
Check that the windows function correctly
in response to operation of switches. Also
check whether or not opening and closing
of the door windows is prevented when the
lock switch is pressed
Sym- Description
bol
1 Driver's door window
FT
2 Front passenger's door window
3 Rear left door window
DOIQP001R11010
4 Rear right door window
5 Lock switch
FRONT LH/RH WINDOW GLASS RUNCHANNEL
CHECK
1. Check window glass operation, ensure win-
RA
dow glass up and down movement is smooth.
2. If window glass operation is not smooth, set
window glass at the lowest position.
3. Clean the surface of the runchannel grove
with clean cloth, especially at PU area.
NOTE
Make sure no dust at the surface.
DOINC042R11007
D
4. Spray along the window glass runchannel

grove with silicon.
Specified silicon:
Oil base silicon (Silicon Emulsion 35 or equi-
valent).
DOINC042R11004

UNDER HOOD / 11
5. Reinspect window glass up and down move-

ment is smooth after the spray.
FT
DOINC042R11003
UNDER HOOD PDI001UHOOD11003
6. ENGINE OIL LEVEL

Check to ensure that the oil level is between
MAX and MIN. If it is at or below MIN, add the
RA
necessary amount of the specified engine oil.
NOTE:
• It is very important to check the engine oil
level regularly and especially before a long
trip.
• It may be necessary to top-up one or several
DOIQP001R11011 times between oil changes and especially
during the running-in of the engine. Top-up
as soon as the oil level reaches the low mark
of the oil gauge
D
• The oil level check must be done when the

vehicle is on as horizontal area, engine
stopped and cold. (Before the first start of
the day)
• When topping up, wait for a time so the oil
can flow (about 2 minutes) before checking
the level with the oil gauge
• It is very important not to go beyond the
upper mark of oil gauge (the oil consumption
will be increased and the engine can be
damaged)
7. BRAKE MASTER CYLINDER FLUID LEVEL
Check the fluid level.
If it is below the ‘‘MIN’’ mark, replenish fresh
brake fluid up to the ‘‘MAX’’ mark.
Specified brake fluid:
DOT 3 or DOT4
DOIQP001R11012

/ 12 UNDER HOOD
8. WASHER FLUID LEVEL

Check the fluid level.
If it is low, replenish the washer fluid.
Symbol Description
A Reservoir tank
B Radiator tank
FT
DOIQP001R11013
9. BATTERY CONDITION AND

CONNECTIONS
Inspect the battery connections:-
- Verify (the battery to be tight off.)
RA
- Clean
NOTE
Do not wipe the lubricant from the battery posts
and cable clamps. Apply petroleum jelly to ter-
minals
DOIQP001R11014
10. POWER STEERING FLUID LEVEL

• Check the fluid level and ensure the fluid
D
level is between “MAX” and “MIN”.

• If the fluid is added, start the engine and
turn the steering wheel from stop to stop
several times to expel air from the system.
Specified gear oil:
Automatic transmission fluid “ATF–9 SPIII”
DOIQP001R11015
11. ELECTRICAL WIRING

1. Check each electrical wiring harness and
connector :
1.1 Make sure that each harness is properly
routed and positively clipped.
1.2 Confirm that all connections are tight.
DOIPP001R10058

UNDER VEHICLE / 13
UNDER VEHICLE PDI001UVEHI11001
12. TYRE AND SPARE TYRE PRESSURES

1. Tyre specification
Check the correct tyre specification.
2. Tyre pressures
Adjust each tyre pressure.
NOTE
Recommended pressure is shown on the tyre
pressure label.
FT
3. Valve stem extensions
DOIIP001R9017 Verify that the valve stem extensions are in-
stalled where necessary.
RA
DOIQP001R11016
13. SUSPENSION SYSTEM

Check and ensure each mounting bolt and nut
D
are tightened.
If split pins are used, make sure the split pins are
properly installed.
1. Lower arm, Upper arm
2. Stabilizer bar and stabilizer link
3. Strut assembly
4. Coil spring
5. Shock Absorber
6. Sub frame
7. Trailing arm
DOIQP001R11035

/ 14 UNDER VEHICLE
14. STEERING LINKAGE AND DRIVER

SHAFT
Steering
1. Steering linkage retaining nuts and split pins
Check visually and feel the steering linkage
retaining nuts are correctly tightened and
the split pins are correctly installed.
2. Check that the tie rods of the steering link-
age are not bent and the tie rods end lock
FT
nuts are securely tightened.
3. Check that each steering components are
DOIQP001R11018 tightened.
4. Check the tie rod end, nuts and split pins are
in proper installation.
5. Check the condition of bellows-type dust
seals.
6. Check split pins at front axle nuts and rear
RA
wheel spindle nuts pins.
Driver Shaft
1. Check the condition the driver shaft are cor-
rectly fitted to transmission and knuckle.
2. Check the condition (grease leak or damage)
of driver shaft boot.
3. Check retaining nuts and split pins
D
DOIQP001R11032
15. UNDER BODY

Body Coating.
1. Check under body and under body coating
for damage.
DOIQP001R11019

BEFORE ROAD TEST / 15
FT
DOIQP001R11033
Check brake hoses and pipes for leakage.

1. Check entire circumference and length of
hoses and pipes, using a mirror as required.
2. Check all clamps for tightness and connec-
RA
tions for leakage.
BEFORE ROAD TEST PDI001BTEST11001
16. SEAT ADJUSTERS AND SEAT BACK

LATCHES
Check the operation of the various parts of the
seats.
1. Mechanical adjusters of the seats
2. Operation of the latch for tilting the seat
D
backs forward and backward.

3. Operation of fold the rear seat back (Rear
seat)
DOIQP001R11020

/ 16 BEFORE ROAD TEST
17. INSTRUMENT PANEL CONTROLS

Check the operation of the following:
1. Horn
2. Head lamp
3. Exterior and interior lamps
4. Instrument panel lamps
FT
DOIQP001R11036
18. METERS, GAUGES, WARNING LAMPS

AND INDICATION LAMPS
1. Check the meters and gauges are functioning
properly.
2. Check the operation of each indicator lamp
RA
and each warning lamp .
DOIQP001R11021
19. AIR CONDITIONING, VENTILATOR AND

DEFROSTER SYSTEM
D
The air conditioning can be operated while the

engine is running.
Operation of controls
Check the system for proper operation
Sym- Description
bol
A Temperature control dail
DOIQP001R11022 B Air selection switch
C Blower speed selection dail
D Air conditioning switch
E Mode selection dail
1. Operate the air conditioning system
2. Operate the air conditioning light
3. Operate the temperature control knob in all
ranges
4. Operate the blower motor switch in all
ranges
5. After the engine has warmed up, turn “ON”
the heater.
6. Move the control to “Defrost” position

BEFORE ROAD TEST / 17
MODE SELEC- AIR OUTLETS

TION
A
A, B
FT
DOIQP001R11023
20. WIPERS AND WASHERS

Front wiper and washer
1. Check operation of the front wipers in all
ranges.
RA
2. Check the aim of the front washer stream.
3. Check the wiper blade-stop positions.
4. Verify that the interval between cycles of
wiping is shifted when timer knob is turned
to any positions.
5. Verify that the front wipers function by op-
erating the washer switch.
DOIQP001R11024
21. OPERATION OF SERVICE BRAKE AND

PARKING BRAKE
D
Symbol Description
A Pedal stroke 135.3 mm
1. Service brake
1.1 Check the brake pedal stroke.
1.2 Verify correct brake pedal free play 2.0
mm MAX.
DOIQP001R11037
2. Parking brake
• Check the parking brake drag and lever
travel.
DOIQP001R11031

/ 18 ROAD TEST
22. CLUTCH OPERATION

1. Check the clutch operation in all driving
ranges.
2. Check the pedal stroke clearance when the
clutch is just disengaged.
3. Verify correct clutch pedal free play
FT
DOIQP001R11038
23. OPERATION OF SEAT BELTS,

SHOULDER BELTS AND RETRACTORS
1. Check all seat belts and harnesses to assure
that they connect and hold properly.
RA
2. Lean forward to check that the shoulder
harnesses allow movement.
3. Check the condition of the belts and anchors.
4. Check for proper seat belt retraction.
DOIHP001R04058
ROAD TEST PDI001RTEST11002
24. ENGINE PERFORMANCE AND

D
EXHAUST GAS
1. Engine performance
Check the engine for proper performance
and accelerator pedal for smooth operation.
2. Exhaust system
2.1 Check the exhaust system components
for gas leaks.
DOIQP001R11026
25. TRANSMISSION IN ALL RANGES

1. Manual transmission
Check the transmission in all forward ranges
and in reverse.
DOIIP001R9031

ROAD TEST / 19
1. CVT
• Make sure shift indicator lines up prop-
erly in all ranges.
• Depress the accelerator completely to
check that the manual kickdown is oper-
ating correctly.
• Stop the vehicle on a steep incline. Put
the CVT in "P" position and slowly re-
lease the service brakes to see if "P" pos-
ition lock holds. If it does not hold, the
FT
transmission requires further service.
While depressing the brake

A pedal, move the selector
lever through the gate.
Move the selector lever
B
through the gate.
26. BRAKES
RA
1. Service brake
• Put the vehicle in gear and apply the
brakes while the vehicle is in motion. Be
sure brake operation is smooth and pos-
itive.
2. Parking brake
• Stop the vehicle on a steep incline.
DOIQP001R11027
With the service brakes firmly applied,
place the transmission in “N” position,
and set the parking brakes.
D
• Slowly release the service brakes to see

if the parking brakes will hold.
27. STEERING CONTROL
1. Check for excessive play or looseness.
2. Check the steering wheel center.
28. VIBRATION AND RATTLES
1. Locate squeaks, rattles and unusual vibra-
tions.
2. Verify that no noise occurs from the engine,
transmission, axle and body.
DOIAW010R3014

/ 20 AFTER ROAD TEST
29. ELECTRICAL EQUIPMENT

1. Radio
• Tune the radio to a local broadcasting
station and check the following:
• Operate the volume, tone, balance and
fader controls, etc.
• Operate the manual/auto seek tuning
buttons and the preset buttons and en-
sure that it functions properly
• Operate the AM/FM switch.
FT
2. CD player
DOIQP001R11030
Insert a CD in the player and check as follows:
• Check the ejection.
• Check the operation of volume, tone,
balance and fader controls, etc.
• Check the operation of CD change mode
button.
• Check stopping (pausing), playback, CD
RA
selection functions.
• Check fast forward, fast backward and
CD track (song) selection functions.
NOTE
For detail operation of the Radio and CD player,
refer to In Car Entertainment manual supplied
with your audio system.
AFTER ROAD TEST PDI001ATEST11003

D
30. VEHICLE DIAGNOSIS

For vehicle diagnosis, ECU, Flashing, Vehicle
measurement and troubleshooting, please use
PADT-II (Proton Advance Diagnosis Tool).
NOTE
Detail refer to workshop Chassis Manual to
troubleshoot problems.
DOIQP001R12001
31. RADIATOR COOLANT LEVEL

CAUTION
Do not remove the radiator cap while the cool-
ing system is under pressure. When removing
the radiator cap, be careful of steam and boiling
water. Add coolant only to the reserve tank if
it is required.
1. Check that the coolant level in the reserve
tank is at or above "LOW" mark at normal
engine operating temperature. And check
cooling system for leaks.
DOIQP001R11028

AFTER ROAD TEST / 21
2. Check that the coolant concentration is 30%

to 60%.
32. HOSES, FLUID LINES AND
CONNECTIONS LOCATED UNDER HOOD
CAUTION
Remember that the air conditioner system is
under pressure.
1. Check all brake, fuel, power steering and air
conditioner lines and connections; Verify
FT
proper routing, check connection for leaks
and tighten loose connector as required.
2. Inspect routing and connections of all vacu-
um, radiator and heater hoses.
DOIQP001R11029
NOTE
Keep in mind that an oily residue around an
air conditioner connector does not necessar-
ily indicate a leak. Oil is used to lubricate
RA
fittings during assembly. Be sure lines are
not twisted or kinked.
33. MANUAL TRANSMISSION OIL LEVEL
1. Remove the filler plug.
2. Check the oil level (A). If the oil level is at or
slightly below the filler hole, it is in satisfact-
ory condition.
3. If the level is low, replenish the transmission
with fresh oil by using lubricator.
D
Note:
For the specified oil, refer to page 2/12
34. ENGINE, TRANSMISSION AND POWER
STEERING UNITS
DOIIP001R9040
Check the engine, transmission and power
steering units for leaks.
35. HOSES, FLUID LINES AND CONNECTIONS LOCATED UNDER VEHICLE
DOIQP002R11009
1. Check all hoses, fluid lines and connection

for leaks.

/ 22 FINAL STEP
2. Check all hoses and fluid lines for proper

routing away from sharp edges and moving
components.
FINAL STEP PDI001FINAL11001
36. HEADLAMP AIMING

Adjust headlamp if necessary as illustrated.
Symbol Description
FT
S Screen
H Headlamp
L Level surface
NOTE
For headlamp aiming procedures, refer to
DOIKP001R03034 Workshop Manual Chassis – Chassis Electrical
(Group 54A).
RA
37. EQUIPMENT
Check the installation of various equipment.
1. Floor mats
2. Spare tyre
3. Jack, jack handle and tool set
D
DOIPP001R10067
38. EXTERIOR AND INTERIOR

Finally check and clean the exterior and interior.
1. Wash the vehicle to remove all traces of road
grime and other dirt on the vehicle as a result
of new vehicle preparations.
2. Clean exterior and interior glass surface.
3. Remove all protective covers.
4. Remove undercoat overspray, excess window
sealer and excess weatherstrip adhesive.
5. Verify that the secondary key can not unlock
the glove box and tailgate/boot lid (if so
DOIQP001R11003
equipped).
6. Remove shipping and inspection stickers.
39. OWNER'S INSTRUCTIONS
1. Verify that the owner's manual and service
booklet is in the glove box.
2. Place the spare keys in envelope in the glove
box before delivery.

PERIODIC INSPECTION AND MAINTENANCE 2
Content /1
2 PERIODIC INSPECTION AND MAINTENANCE

PERIODIC INSPECTION AND MAINTENANCE SCHEDULE ...................... 2/2
MAINTENANCE OPERATION ...................................................... 2/2
OPERATION INSIDE THE ENGINE COMPARTMENT .............................. 2/3

OPERATIONS MAINTENANCE .................................................... 2/3
1. CHECK FEAD BELT FOR CRACKS , FRAYING OR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/3
2. REPLACE ENGINE TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/4
3. REPLACE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/4
4. CHECK RADIATOR HOSES FOR DAMAGE AND PROPER CONNECTION . . . . . . . . . . . . . . 2/4
FT
5. CHECK ENGINE COOLANT LEVEL IN RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/5
6. CHANGE ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/5
BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/6
7. CHECK AIR CLEANER ELEMENT FOR CLOGGING AND DAMAGE . . . . . . . . . . . . . . . . . . . . 2/7
8. REPLACE AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/7
9. CHANGE AUTOMATIC TRANSMISSION FLUID (CVT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/8
10. CHANGE CVT OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/8
11. CHECK FLUID LEVEL IN BRAKE/CLUTCH OIL RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 2/8
12. CHANGE BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/9
13. CHECK BATTERY VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/10
RA
14. REPLACE FUEL FILTER (Except filter in tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/10
OPERATIONS INSIDE THE VEHICLE ................................................ 2/11

OPERATION MAINTENANCE ...................................................... 2/11
15. CHECK PARKING BRAKE STROKE AND PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/11
16. REPLACE AIR PURIFIER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/11
OPERATION UNDER THE VEHICLE ................................................. 2/12

17. CHECK SUSPENSION SYSTEM FOR DAMAGE AND LOOSENESS . . . . . . . . . . . . . . . . . . . . 2/12
18. CHECK SUSPENSION ARM BALL JOINTS FOR PLAY, AND DUST COVERS FOR DAMAGE 2/12
.......................................................................................
D
19. CHECK DRIVE SHAFT BOOTS FOR DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/12

20. CHECK STEERING LINKAGE FOR DAMAGE AND LOOSE CONNECTIONS (INCLUDING 2/13
SEALS AND BOOTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21. CHANGE GEAR OIL IN MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/13
Transmission oil refilling: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/14
22. CHECK EXHAUST PIPE CONNECTIONS FOR GAS LEAKAGE, AND CHECK PIPE INSTALL- 2/15
ATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATIONS OUTSIDE THE VEHICLE .............................................. 2/16

OPERATIONS MAINTENANCE ..................................................... 2/16
23. CHECK BRAKE HOSES AND PIPES FOR LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/16
24. CHECK BRAKE PADS AND DISC FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/16
25. CHECK FUEL HOSES AND PIPES FOR LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/17
OPERATION AFTER ENGINE IS WARMED UP ..................................... 2/17

26. CHANGE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2/17
SELECTION OF ENGINE OIL ........................................................ 2/18
27. REPLACE ENGINE OIL FILTER ................................................. 2/18
28. CHECK VALVE CLEARANCE (For CFE engine only) ....................... 2/19
29. CHECK BODY CONDITION FOR DAMAGE ................................. 2/19
30. ROAD TEST ...................................................................... 2/19

/2 PERIODIC INSPECTION AND MAINTENANCE SCHEDULE
PERIODIC INSPECTION AND MAINTENANCE SCHEDULE PDI002PMAIN11003
MAINTENANCE OPERATION
For items which indicate both distance and time (in months), the inspection should be made at
whichever (distance or time) comes first.
Maintenance operation code: -
Maintenance operation code
I : Inspection
R : Replace or change
FT
Service Intervals
(Odometer reading or months, whichever occurs first)
Items
Months — 6 12 18 24 30 36 42 48 54 60
Odometer reading x1,000 km 1 10 20 30 40 50 60 70 80 90 100
OPERATIONS INSIDE THE ENGINE COMPARTMENT
Check fead belt or auxiliaries belt for cracks,
1. R : every 100,000 km (5 years)
fraying or wear
RA
2. Replace engine timing belt R : every 100,000 km (5 years)
3. Replace spark plugs R
Check radiator hoses for damage, and proper
4. I I I I I I
connection
5. Check engine coolant level in reservoir I I I I I I I I I I I
6. Change engine coolant R R R
Check air cleaner element for clogging and
7. I I I I I I I I I I I
damage
8. Replace air cleaner element R R
D
9. Change automatic transmission fluid (CVT) R

10 Chnage CVT oil filter R
Check fluid level in brake reservoir and clutch
11. I I I I I I I I I
reservoir (for hydraulic-type clutch only)
12. Change brake fluid R R
13. Checking battery voltage I I I I I I I I I I I
14 Replace fuel filter (Except filter in tank) R
OPERATIONS INSIDE THE VEHICLE
15. Check parking brake stroke and play I I I I I
16 Replace air purifier filter I I R I R I R I R I R
OPERATIONS UNDER THE VEHICLE
Check suspension system for damage and
looseness
Check suspension arm ball joints for play, and
dust covers for damage
19. Check drive shaft boots for damage I I I I I
Check steering linkage for damage and loose
connections (including seals and boots)
21. Change gear oil in manual transmission R
Check exhaust pipe connections for gas leak-
22. I I I
age, and check pipe installation

OPERATION INSIDE THE ENGINE COMPARTMENT /3
Service Intervals
(Odometer reading or months, whichever occurs first)
Items
Months — 6 12 18 24 30 36 42 48 54 60
Odometer reading x1,000 km 1 10 20 30 40 50 60 70 80 90 100
OPERATIONS OUTSIDE THE VEHICLE
23. Check brake hoses and pipes for leakage I I I I I I I I I I I
24. Check brake pads and discs for wear I I I I I I I I I I I
25. Check fuel hoses and pipes for leakage I I I I I I I I I I I
FT
OPERATIONS AFTER ENGINE IS WARMED UP
26. Change engine oil R R R R R R R R R R R
27. Replace engine oil filter R R R R R R R R R R R
Check valve clearance (except vehicle with auto
28. I
adjuster)
29. Check body condition for damage I : Every year (12 months)
30. Road test I I I I I I I I I I I
RA
NOTE
Should your vehicle be used frequently under severe operating conditions, certain parts of vehicle
will require more frequent maintenance. An Authorized PROTON dealer should be able to advise of
these requirements. Severe operating conditions include the following cases :
(1) Driving on dusty area or in an area in which the vehicle is likely to be exposed to salty air
(2) Driving on rough roads, on submerged roads, or hilly areas
(3) Engine idling for a long time or short distance travel during cold weather
(4) Frequent, sudden application of brakes
(5) Use as a rental car or as a taxi
(6) Operation under excessive load
(7) More than 50% of operation time in heavy city traffic in hot temperatures of 32 °C (89.6 °F) or
D
higher
(8) Overloading
(9) Operation in extremely hot weather condition
PROTON reserve the right to alter service schedule content and time/mileage content at any time.
OPERATION INSIDE THE ENGINE

COMPARTMENT PDI002ICOMP11003
OPERATIONS MAINTENANCE
1. CHECK FEAD BELT FOR CRACKS , FRAYING OR
WEAR
DRIVE BELT CONDITION
Check all round of the drive belt for cracks,
fraying, and wear.
1. DRIVE BELT TENSION
DOIHP001R04071 NOTE
Require Automatic Tensioner by (E)
Symbol Description
A Crankshaft pulley
B Air conditioning compressor
C Alternator

/4 OPERATION INSIDE THE ENGINE COMPARTMENT
Symbol Description
D Power steering pump
E Automatic tensioner pulley
F Water pump pulley
2. REPLACE ENGINE TIMING BELT
For information concerning the replacement
procedures, refer to the Workshop Manual
Chassis (Group 11A).
FT
DOINP001R11010
RA
3. REPLACE SPARK PLUGS
After removing old spark plugs, install new spark
plug and tighten at the specified torque.
Symbol Description
1 Ignition coil
2 Spark plug
T2 2.0-3.0 kgm (20-30 Nm, 14.47-21.7
ft.lbs)
D
DOINP001R11011
4. CHECK RADIATOR HOSES FOR DAMAGE AND

PROPER CONNECTION
hoses, using a mirror as required.
2. Check that hoses installed in grommets pass
through the centre of the grommets.
tions for leakage.
DOIQP001R11029

5. CHECK ENGINE COOLANT LEVEL IN RESERVOIR

Check that the coolant level is between the
“FULL” and “LOW” or “MAX” and 'MIN' lines
when the engine is at the normal operating
temperature.
FT
DOIHP001R04064
6. CHANGE ENGINE COOLANT

1. Symbol Description
A Radiator cap
B Drain plug (radiator)
RA
C Reserve tank
D Tighten
Check that the drain plug is screwed on
tightly.
DOIHP001R04075
2. Open the bleed screw (B)

3. Fill in the coolant through the radiator upper
D
tank (open cap)

4. Close the bleeder screw as soon as coolant
flows out in a continuous jet from the
bleeder
Symbol Description
A Water pipe
B Bleed screw
T1 Torque value : 1.2 kg (12 N, 2.65
lbs) ~ 1.5 kg (15 N, 3.31 lbs)
DOIMP002R07004
5. Start the engine and rev at 2500 rpm
Symbol Description
1 START ⇒ Position
A Depress the accelerator pedal ⇒
Rev engine until 2500 rpm
B 2500 rpm meter position
DOIQP002R11011

Symbol Description
C Coolant reservoir
6. Adjust the coolant level by adding coolant
inside the expansion tank such that it over-
flows for a period of a 4 minutes while rev-
ving engine at 2500 rpm. (During this 4
minutes period & at 2500 rpm, make sure
close the radiator upper tank with its cap.
FT
DOIMP002R07006
BLEEDING PROCEDURE
1. Rev the engine at 2500 rpm for 20 minutes
until the radiator fan auto-stops (Fan auto-
starts when engine is warm and then auto-
stops).
RA
Symbol Description
A 20 minutes
C Radiator fan auto-stops
DOIQP002R11012
2. Make sure that the coolant level is close to

the “MAX” level. If not, add or take out
D
some coolant so that it is close to “MAX”

level.
CAUTION
(1) Do not open or leave open the bleeder
screw when engine is running.
(2) Retighten the expansion tank cap when
the engine is warm.
Symbol Description
DOIHP001R04080
A Coolant cap (closed)
B “MAX” level
C Coolant at correct level ⇒ (Add
or pump coolant out)
D Pump hose
E Pump
RECOMMENDED ANTIFREEZE
Antifreeze Allowable concentra-

tion range
Weston 936 25% – 35%


tion range
Quantity of coolant Standard value : ap-
prox. 7 liters or make
sure the coolant is
filled and bleed as ex-
plained above
7. CHECK AIR CLEANER ELEMENT FOR CLOGGING
AND DAMAGE
FT
1. Check air cleaner element for clogging and
damage
2. Clean deposited dust from the element in
the following manner
– Blow compressed air from inside the ele-
ment
3. Wipe off dust on the air cleaner interior
8. REPLACE AIR CLEANER ELEMENT
RA
The air cleaner element will become dirty and
DOIMP002R07014 loaded with dust during use, and the filtering
effect will be substantially reduced. Replace it
with a new one.
1. Open the air cleaner cover clip.
2. Remove the air cleaner element and install
a new one.
3. Be sure close the air cleaner cover completely
when clamping it.
D
Symbol Description
1 Air Cleaner cover
2 Air Cleaner element
DOIQP002R11013

9. CHANGE AUTOMATIC TRANSMISSION FLUID

(CVT)
1. Detail, refer to WORKSHOP MANUAL for re-
placement procedures.
Specified automatic transmission fluid (CVT):
ESSO EZL799
FT
RA
DOIMC023R11044
10. CHANGE CVT OIL FILTER

1. Remove the oil filter (A).
D
2. Detail, refer to WORKSHOP MANUAL for re-

placement procedures.
DOINP001R11001
11. CHECK FLUID LEVEL IN BRAKE/CLUTCH OIL

RESERVOIR
1. Check that the fluid level is between the
“MAX” and “MIN” marks
2. If it is below the”MIN” mark, replenish with
fresh brake fluid up to the “MAX” mark.
Note:
For clutch oil bleeding refer to Workshop
Manual Chassis – GROUP 35B (Brake oil bleeding)
and GROUP 21, (Clutch oil bleeding)
DOINP001R09042

12. CHANGE BRAKE FLUID

1. Remove the cap of the bleed screw, connect
a vinyl tube and place its other end in a re-
ceptacle
2. Loosen the bleed screw and depress the
brake pedal. Add new brake fluid when the
level of the fluid within the reservoir tank
decreases.
CAUTION
FT
If the reservoir tank completely runs out of fluid
during operation, air will find its way into the
DOIQP002R11002 brake line. Pay attention, to the fluid level and
replenish as necessary.
Specified brake fluid:
DOT4
CAUTION
Use the specified brake fluid. Avoid using a
RA
mixture of the specified brake fluid and other
fluid. If brake fluid is exposed to the air. it will
absorb moisture; as water is absorbed from the
atmosphere, the boiling point of the brake fluid
will decrease and the braking performance will
be seriously impaired. For this reason, use a
hermetically sealed 1 lit (1.05 U.S.qts, 0.87
Imp.qts) or 0.5 lit (0.53 U.S.qts, 0.43 Imp.qts)
brake fluid container. Firmly close the cap of the
brake fluid container after use.
D
3. When fresh fluid flows out to the vinyl tube,

tighten the bleed screw.
NOTE
This change from existing to fresh can be judged
by change in colour of fluid that flows out.
4. Repeat above steps for other bleed screws.
NOTE
The operation steps for each bleeder screw is il-
lustrated on this page .
DOIHP001R04084

/ 10 OPERATION INSIDE THE ENGINE COMPARTMENT
13. CHECK BATTERY VOLTAGE

1. Check the vehicle electrical system. Make
sure that the alternator / generator and
voltage regulators are functioning properly.
Charging voltage limits of the alternator
should be between 14.4 volts to 14.8 volts.
2. Inspection of battery voltage to check its
State of Charge (SOC) and determine
whether it is fully charged or need to be re-
charged.
FT
3. Battery with voltage less than 12.25 volt [at
Specific Gavity (SG) of 1.255] and 12.35 volt
DOIJP002R06003
(at SG of 1.280) must be recharged according
to Battery Recharging Guide.
WARNING:
For “Battery Maintenance Free” do not re-
move the sticker, it will avoid warranty of
the battery.
RA
Country SG level
Malaysia (tropical countries) 1.255
and GCC
Europe and Australia 1.280
NOTE:
For detail recharging procedure, refer to
Workshop Manual Chassis – GROUP 054,
Chassis Electrical - (Battery)
D
14. REPLACE FUEL FILTER (Except filter in tank)

1. Bleed the residual pressure from inside fuel
line. The fuel pressure in the fuel pipe is high,
please following so as to release the fuel
pressure to prevent from running out.
• Disconnect fuel wiring harness.
• After starting the engine and letting it
run until it stops naturally, turn the igni-
tion switch OFF.
2. Disconnect the high-pressure fuel hose
3. Disconnect the main pipe connection
DOIQP001R11034 4. Remove the fuel filter
5. After install new fuel filter. tighten main pipe
nut.
6. Connect the high-pressure fuel hose
7. Connect the fuel wiring harness
8. After start engine, check that there are no
fuel leaks

OPERATIONS INSIDE THE VEHICLE / 11
OPERATIONS INSIDE THE VEHICLE

PDI002IVEHI11001
OPERATION MAINTENANCE
15. CHECK PARKING BRAKE STROKE AND PLAY
1. Pull the parking brake lever with a force of
approx. 20 kg (200 N, 44.1 lbs)
Standard value : 5–6 notches
2. If the number of notches is not within the
FT
standard value, turn the adjusting nuts to
DOIQP001R11031 increase or reduce the cable length for adjust-
ment.
3. Using a tester, check if the vehicle can be
held stationary on a dry slope, or while driv-
ing the vehicle at a low speed, pull the
parking brake lever to check brake opera-
tion.
RA
16. REPLACE AIR PURIFIER FILTER
1. Remove the glove box.
2. Remove the air purifier cover and the air
purifier assembly.
3. Install a new air purifier (B) assembly and in-
stall the air purifier cover.
4. Install the glove box.
D
DOIQP002R11003

/ 12 OPERATION UNDER THE VEHICLE
OPERATION UNDER THE VEHICLE

PDI002UVEHI11003
17. CHECK SUSPENSION SYSTEM FOR DAMAGE
AND LOOSENESS
Check and ensure each mounting bolt and nut
are tightened.
If split pins are used, make sure the split pins are
properly installed.
FT
1. Lower arm, Upper arm
2. Stabilizer bar and stabilizer link
3. Strut assembly
4. Coil spring
5. Shock Absorber
6. Sub frame
RA
DOIQP001R11017
18. CHECK SUSPENSION ARM BALL JOINTS FOR

PLAY, AND DUST COVERS FOR DAMAGE
D
BALL JOINTS FOR PLAY

1. Verify that there is no play in the ball joint
between the lower arm and knuckle.
DUST COVERS FOR DAMAGE
1. Check dust covers for damage
DOIQP002R11004
19. CHECK DRIVE SHAFT BOOTS FOR DAMAGE

1. Check the drive shaft boots for damage
DOIQP001R11032

OPERATION UNDER THE VEHICLE / 13
20. CHECK STEERING LINKAGE FOR DAMAGE

AND LOOSE CONNECTIONS (INCLUDING SEALS
AND BOOTS)
1. Move the steering wheel bit by bit to the left
or right and check to be sure that there is no
play or looseness in the linkage coupling,
installation is not loose and rod or arm is not
bent or damaged.
FT
DOIQP001R11018
2. Check to be sure that seal and boot of the

ball joint (A) are correctly installed (in the
correct position), and not damaged.
3. Check tie-rod end lock nut (B) for looseness.
If lock nut is loose, adjust toe-in and then
RA
tighten lock nut to the specified torque.
Symbol Description
A Seal and boot of the ball joint
B Lock nut
Torque :4.2 kgm (42 Nm, 30.38 ft.lbs)
DOINP002R09007
21. CHANGE GEAR OIL IN MANUAL

TRANSMISSION
D
1. Remove the drain plug and then drain the

transmission oil.
DOIMC022R11004

/ 14 OPERATION UNDER THE VEHICLE
2. If all transmission oil come out, install it drain

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

1. Disconnect speedometer connector and re-
move the speedometer.
RA
DOIMC022R11005
2. Disconnect the reverse lamp switch connector

and remove the reverse lamp switch.
D
DOIMC022R11001

OPERATION UNDER THE VEHICLE / 15
Fill new transmission oil into the speedometer

hole as shown in the illustration.
Specified transmission oil:
Castrol BOT130M WSD-M2C200–C
Quantity: 1.8 litre.
FT
DOIMC022R11006
3. Ensure the transmission oil come out from

reverse lamp switch hole, if transmission oil
not come out, refill transmission oil.
RA
DOIMC022R11002
4. Install the reverse lamp switch and tighten

to the specified torque.
D
Tightening torque:
2.0~2.5 kgm (20~25 Nm, 14.47~18.08 ft.lbs)
DOIMC022R11007
22. CHECK EXHAUST PIPE CONNECTIONS FOR

GAS LEAKAGE, AND CHECK PIPE INSTALLATION
1. Confirm that the exhaust pipe does not inter-
fere with body components.
2. Check the exhaust pipe for damage by
stones, etc.
3. Start the engine and check for leaks from
the exhaust pipe connections.
DOIQP001R11026

/ 16 OPERATIONS OUTSIDE THE VEHICLE
OPERATIONS OUTSIDE THE VEHICLE PDI002OVEHI11001
OPERATIONS MAINTENANCE
FT
DOIQP001R11033
23. CHECK BRAKE HOSES AND PIPES FOR

LEAKAGE
RA
tions for leakage.
24. CHECK BRAKE PADS AND DISC FOR WEAR
1. Check the thickness of the pads or signs of
irregular wear through caliper body check
port.
Standard value :
D
Items Standard value

Pad Thickness Min 2.0 mm
Max 10.0 mm
DOIQP002R11007
2. Check the discs for wear or runout.

Front disc thickness
Standard value :
Limit : 14 inch disc brake (Ventilated type )

24.0 mm (Std)
Front disc
22.4 mm (min)
DOIIC35AR9023

OPERATION AFTER ENGINE IS WARMED UP / 17
Standard value disc runout :

Items Specifications
Front disc runout 0.04 mm (0.002 in) or
less
FT
DOIQP002R11006
25. CHECK FUEL HOSES AND PIPES FOR LEAKAGE

RA
DOIQP002R11009

D

tions for leakage.
OPERATION AFTER ENGINE IS

WARMED UP PDI002EWARM11003
26. CHANGE ENGINE OIL
1. Remove the engine oil filler cap, located at
the upper part of the cam cover.
2. Remove the drain plug of the engine oil pan
(B) and drain out the engine oil.
3. Tighten the drain plug.
4. Fill the crankcase with fresh oil through the
DOIMP002R07013 filler port.

/ 18 OPERATION AFTER ENGINE IS WARMED UP
Oil quantity <S4P> : 4.0 lit
Includes volume inside oil filter : 0.3 lit
5. Remove the dipstick from the engine, and

check that the engine oil level is within the
range between MAX and MIN.
6. Install the filler cap.
7. Recheck the level of the engine oil after a
road test.
FT
DOIHP001R04029
SELECTION OF ENGINE OIL

1. Use engine oil to the following API classifica-
tion:
Engine oil API classification
Standard value <S4P>: SERVICE SJ” or higher
RA
2. Select engine oil of the proper SAE viscosity
number according to the atmospheric tem-
perature. (A-Barometric temperature)
DOIHP001R04094
CAUTION
Please clean oil cap and cam cover sealing face
D
from oil trace/debris using soft cloth during

change or top-up.
DOIMP002R07003
27. REPLACE ENGINE OIL FILTER

1. Use a filter wrench (available commercially)
to remove the oil filter.
2. Drain oil from the oil filter.
3. Apply a small amount of engine oil to the O-
ring (A) of the new oil filter. Use an oil filter
wrench to tighten oil filter
4. Install the drain plug and refill the engine
oil.
5. Race the engine 2–3 times and check to be
sure that no engine oil leaks from installation
DOIHP001R04096
section of the oil filter.

OPERATION AFTER ENGINE IS WARMED UP / 19
28. CHECK VALVE CLEARANCE (For CFE

engine only)
1. The tappet clearance measurements should
only be done after a minimum 2 hours of
soaking.
2. Ensure that cam sprocket timing marks in
line with cam cover timing marks (crank is
90° ATDC).
3. Cylinder head must be clamped with cylinder
block to get achieve precise tappet clearance.
FT
4. Rotate cam sprocket clockwise direction as
DOIQP002R11010 below sequence and measure the clearance
using thickness gauge.
Tappet clearance specification:
Type Specification
Intake 0.2 mm ± 0.05 mm
Exhaust 0.3 mm ± 0.05 mm
RA
NOTE
For detail the Inspection procedure refer to
Workshop Engine Overhaul.
29. CHECK BODY CONDITION FOR
DAMAGE
1. Check underbody coating for damage
2. Check body painting for damage
30. ROAD TEST
D
Drive the vehicle and check for conditions

1. Check free play of steering wheel.
2. Check efficiency of service brakes and park-
ing brakes system.
3. Check driveability of engine.
DOIQP001R11003 4. Check condition of instruments gauge indic-
ators, exterior lamps and ventilators.
5. Check abnormal noise of each part.
6. Check the tyres for wear and correct air
pressure.

/ 20 OPERATION AFTER ENGINE IS WARMED UP
NOTE
FT
RA
D

WORKSHOP MANUAL ALL
Index /1
Air conditioning.............................................. 1/16

automatic transmission ................................... 2/8
FT
RA
D

CR Model YR 2012 English Edition RDCE-1200CR050-00 February 2012 Printed in Malaysia
WORKSHOP MANUAL
CHASSIS
CR AF
T
R
D
Model YR 2012
Destination: MHR
Copyright ©
Perusahaan Otomobil
Nasional Sdn. Bhd.
T
AF
R
D

WORKSHOP MANUAL ALL
Group Index /I
00 GENERAL ................................................................................... 00/1 - 00/33

11A ENGINE <CFE> ....................................................................... 11A/1 - 11A/82
11A ENGINE <IAFM+> ................................................................... 11A/1 - 11A/74
12 LUBRICATION ............................................................................... 12/1 - 12/8
13A FUEL <CFE> .......................................................................... 13A/1 - 13A/205
13A FUEL <IAFM+> ..................................................................... 13A/1 - 13A/189
14 COOLING <CFE> ......................................................................... 14/1 - 14/31
14 COOLING <IAFM+> ..................................................................... 14/1 - 14/23
15 INTAKE AND EXHAUST <CFE> ..................................................... 15/1 - 15/52
15 INTAKE AND EXHAUST <IAFM+> ................................................ 15/1 - 15/16
16 ENGINE ELECTRICAL ................................................................... 16/1 - 16/61
17 EMISSION CONTROL<CFE> ......................................................... 17/1 - 17/29
17 EMISSION CONTROL<IAFM+> ..................................................... 17/1 - 17/15
21
22
T
CLUTCH ...................................................................................... 21/1 - 21/20
MANUAL TRANSMISSION ........................................................... 22/1 - 22/27
AF
23 CVT .......................................................................................... 23/1 - 23/270
31 WHEEL AND TYRE ........................................................................ 31/1 - 31/8
32 POWER PLANT MOUNT .............................................................. 32/1 - 32/18
33A FRONT SUSPENSION .............................................................. 33A/1 - 33A/20
R
34 REAR SUSPENSION ..................................................................... 34/1 - 34/24

35A BASIC BRAKE SYSTEM ........................................................... 35A/1 - 35A/42
35B ABS ........................................................................................ 35B/1 - 35B/24
D
35C ESC ...................................................................................... 35C/1 - 35C/103

36 PARKING BRAKES ......................................................................... 36/1 - 36/6
37A STEERING .............................................................................. 37A/1 - 37A/41
42 BODY ......................................................................................... 42/1 - 42/64
51 EXTERIOR ................................................................................... 51/1 - 51/51
52A INTERIOR ............................................................................... 52A/1 - 52A/42
52B SRS ...................................................................................... 52B/1 - 52B/124
54 CHASSIS ELECTRICAL ................................................................ 54/1 - 54/242
55 HEATER, AIR CONDITIONER AND VENTILATION ........................... 55/1 - 55/48

ALL WORKSHOP MANUAL
/ II Group Index
NOTE
T
AF
R
D

GENERAL 00
Content /1
00 GENERAL
FOREWORD ............................................................................ 00/4
RELATED PUBLICATION MANUAL ............................................... 00/4
AIR BAG SYSTEM INFORMATION ................................................ 00/4

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS .... 00/4
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/5
DEFINITION OF TERMS ............................................................. 00/5
Standard Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/5
Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/5
Reference Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/5
Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/5
INDICATION OF TIGHTENING TORQUE ......................................... 00/5
MODEL INDICATIONS .............................................................. 00/5
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS .......... 00/9

TROUBLESHOOTING CONTENTS ................................................. 00/9
T
1. Standard Flow of Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/9
2. System Operation and Symptom Verification Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/10
3. Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/10
4. Inspection Chart for Diagnosis Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/10
AF
5. Inspection Procedure for Diagnosis Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/10
7.Inspection Procedure for Trouble Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/10
8. Service Data Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/10
9. Check at ECU Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/11
10. Inspection Procedures Using an Oscilloscope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/11
DIAGNOSIS FUNCTION ............................................................. 00/11
Method of Reading Diagnosis Codes When Using PADT-II . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/11
Method of Erasing Diagnosis Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/11
R
HOW TO USE THE INSPECTION PROCEDURES ................................. 00/12

Harness Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/12
Action Taken After Replacing The ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/13
CONNECTOR MEASUREMENT SERVICE POINTS ............................... 00/13
D
If Inspecting With The Connector Connected (With Circuit In A Condition Of Continu- 00/13
ity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If Inspecting With The Connector Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/13
CONNECTOR INSPECTION ......................................................... 00/14
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/14
CONNECTOR PIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/15
CONNECTOR ENGAGEMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/15
INSPECTION SERVICE POINTS FOR A BLOWN FUSE ........................... 00/15
POINT TO NOTE FOR INTERMITTENT MALFUNCTIONS ...................... 00/16
VEHICLE IDENTIFICATION ............................................................ 00/16

VEHICLE INFORMATION CODE PLATE ........................................... 00/16
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/16
Code Plate Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/17
MODELS ............................................................................... 00/17
4-DOOR SEDAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/17
MODEL CODE ........................................................................ 00/17
CHASSIS NUMBER ................................................................... 00/18
Location 1 (under driver seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/18
Location 2 (under rear seat cushion, right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/18
ENGINE MODEL AND SERIAL NUMBER ......................................... 00/19
TRANSMISSION MODEL AND SERIAL NUMBER ............................... 00/20

00 GENERAL
/2 Content
Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/20

Continuous Variable Transmission (CVT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/20
MAJOR SPECIFICATIONS ............................................................. 00/21

4-DOOR SEDAN ..................................................................... 00/21
PRECAUTION BEFORE SERVICE ..................................................... 00/22

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE- 00/22
TENSIONER ...........................................................................
SERVICING THE ELECTRICAL SYSTEM ........................................... 00/23
APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS ........ 00/23
PRE-INSPECTION CONDITION ..................................................... 00/23
VEHICLE WASHING ................................................................. 00/23
PROTON ADVANCE DIAGNOSTIC TOOL–II (PADT-II) ......................... 00/24
IN ORDER TO PREVENT VEHICLE FROM FIRE .................................. 00/24
ENGINE OILS ......................................................................... 00/24
Health Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/24
Recommended and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/25
TENSIONER .............................................................................
SEAT BELT WITH PRE-TENSIONER ................................................
SUPPORT LOCATIONS FOR LIFFTING AND JACKING ...........................

T 00/28
00/29
AF
SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS .......... 00/29
SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT ... 00/30
SUPPORT POSITION AND SUPPORT METHOD FOR AN H-BAR LIFT ....... 00/31
PREPARATION OF “ATTACHMENTS” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/32
TIGHTENING TORQUE ............................................................... 00/32

Standard bolt and nut tightening torque ..................................... 00/33
R
Flange bolt and nut tightening torque ........................................ 00/33

D

GENERAL 00
Content /3
NOTE
T
AF
R
D

00 GENERAL
/4 FOREWORD
FOREWORD WCH000FWORD11001
This Workshop Manual contains procedures for service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and installation.
The publications shown on the following page are also available, and should be used in conjunction
with this manual
RELATED PUBLICATION MANUAL
Manual type Publication Number
CHASSIS RDCE-12000CR010
ENGINE OVERHAUL RDCE-110S4P020–024
TRANSMISSION AND CLUTCH OVERHAUL
• CVT Transmission RDCE-11PNCH080–00
• Manual Transmission RDCE-11GTRG080–00
ELECTRICAL WIRING RDCE-12000CR030
FLAT RATE RDCE-12000CR040
PRE-DELIVERY INSPECTION RDCE-12000CR050
BODY REPAIR RDCE-12000CR060
T
All information, illustration and product descriptions contained in this manual are current as the time
of publication. We however reserve the right to make changes at any time without prior notice or
obligation.
AF
AIR BAG SYSTEM INFORMATION
WARNING
(1) Improper service or maintenance of any components of the SRS or any SRS — related components,
can lead to personal injury or death to service personnel (from inadvertent firing of the air bag)
or to the driver and passenger (from rendering the SRS inoperative).
R
(2) SRS components should not be subjected to heat over 85 °C (185 °F),
so remove the SRS-ECU, air bag module and clock spring before drying or baking the vehicle after
painting.
(3) Service or maintenance of any SRS components or SRS-related components MUST BE performed
D
only at an Authorized dealer.

(4) Dealer personnel must thoroughly review this manual, and especially in MODULE 1.10; GROUP
52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any
components of the SRS or any SRS-related components.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring
warnings.
HOW TO USE THIS MANUAL WCH000HUSEM11001
SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS

This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however for engine and transmission-related component
parts, this manual covers only on-vehicle inspections, adjustments and the removal and installation
procedures for major components. For details information concerning the inspection, checking, ad-
justment, disassembly and reassembly of the engine, transmission and major components after they
have been removed from the vehicle, please refer to separate manuals covering the engine and
transmission.

GENERAL 00
FOREWORD /5
On-Vehicle Service
“On-Vehicle Service” is a procedures for performing inspections and adjustment of particularly import-
ant locations with regards to the construction and for maintenance and servicing, but other inspection
(for looseness, play, cracking, damage and etc) must also be performed.
Inspection
“Inspection” means the inspection and checking procedures to be performed by using special tools
and measuring instruments and by feeling. Visual inspections should always be performed as well for
actual maintenance and servicing procedures.
DEFINITION OF TERMS
Standard Value
Indicates the value as standard for judging the quality of a part of assembly on inspection or the value
to which the part or assembly is corrected and adjusted. It is given by tolerance.
Limit
Shown the standard for judging the quality of a part or assembly on inspection and means the max-
imum or minimum value within which the part or assembly must be kept functionally or in strength.
It is a value established outside the range of standard value.
T
Reference Value
Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly
and adjustment procedures, and so they can be completed in a shorter time).
AF
Caution
Indicates the presentation of information particularly vital to the worker during the performance of
maintenance and servicing procedures in order to avoid the possibility of injury to the worker, or
damage to component parts, or a reduction of component or vehicle function or performance, etc.
INDICATION OF TIGHTENING TORQUE
R
The tightening torque shown in this manual is a basic value with a tolerance of ± 10% except the
followings cases when the upper and lower limits of tightening torque are given;
1. The tolerance of the basic value is within ± 10%
D
2. Special bolts or the like are in use

3. Special tightening methods are used.
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.
Abbreviation Description
Indicates the manual transmission, or models equipped with
M/T
the manual transmission
Indicates the automatic transmission or models equipped
A/T
with automatic transmission
Indicates the automated-manual transmission or models
AMT
equipped with automated-manual transmission
Indicates an engine with a single overhead camshaft, or a
SOHC
model equipped with such engine
Indicates an engine with a double overhead camshaft, or a
DOHC
Indicates the multi-point injections or engine equipped the
MPI
multi-point injection

00 GENERAL
/6 FOREWORD
Abbreviation Description
2WD Indicates the front wheel-drive vehicles
A/C Indicates the air-conditioner
ECU Indicates the electronic control unit
SRS Indicates the Supplementary Restraint System
ABS Indicates the Anti-lock Brake System
Indicates an engine with CAM Profile Switching, or a model
CPS
equipped with such engine
Indicates an engine with Intake Air Flow Manifold or a model
IAFM
equipped with such engine
Indicates an engine with Variable Intake Manifold, or a
VIM
Indicates the continuously variable transmission or models
CVT
equipped with continuously variable transmission
T
AF
R
D

GENERAL 00
FOREWORD /7
T
AF
R
D
DOIIC000R9001

00 GENERAL
/8 FOREWORD
SYMBOL DESCRIPTION
E Component Diagram
A diagram of the component parts is provided near the front of each section in order
to give a reader a better understanding of the installed condition of the component
parts.
F Denotes non reusable part
G Denotes tightening torque.
For bolts and nuts which do not have a tightening torque listed, refer to the “Tighten-
ing torque”
H Symbol for lubrication sealants and adhesives.
Information concerning the locations for lubrication and for application of sealants
and adhesives is provided, by using symbols, in the diagrams of component parts or
on the page following the component parts page, and explained.
DOIIC000R9058
T
Grease (multipurpose grease unless there is a brand
or type specified)
AF
Sealant or adhesive
DOIIC000R9059
Brake fluid or automatic transmission fluid

R
DOIIC000R9060
Engine oil, gear oil or air condition compressor oil

D
DOIIC000R9061
Adhesive tape or butyl rubber tape.

DOIIC000R9062
Indicates procedures to be performed before the work in that section is started, and
J
procedures to be performed after the work in that section is finished.
Maintenance and servicing Procedures
The number provided within the diagram individual the sequence for maintenance
and servicing procedures.
1. A diagram of the components part is provided near the front of each section in
K order to give the reader a better understanding of the installed condition of
component parts.
2. The number provided within the diagram indicate the sequence for maintenance
and servicing procedures; the symbol N indicates a non reusable part; the tightening
torque is provided where applicable.
Removal steps:
The part designation number correspond to the number in the illustration to indicate
removal steps.

GENERAL 00
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS /9
SYMBOL DESCRIPTION
Disassembly steps:
disassembly steps.
Installation steps:
Specified in case installation is impossible in reverse order of removal steps
Reassembly steps:
Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted
if reassembly is possible in reverse order of disassembly steps.
Classifications of major maintenance/service points
When there are major points relative to maintenance and serving procedures (such as
L essential maintenance and service points, maintenance and service standard values,
information regarding the use of special tools, etc.) these are arranges together as
major maintenance and service points and explained in detail.
Indicates that there are essentials point for removal

or disassembly.
DOIIC000R9052
T
Indicates that there are essential point for installation
or reassembly
DOIIC000R9051
AF
Indicates that there are essential points for both
DOIIC000R9053
M Operating procedures, caution etc. on removal, installation disassembly and reassembly

are described.
N Table for graphic explaination
R
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS WCH000TSHOT11001

When performing troubleshooting for electronic control systems using PADT-II, basic outline described
D
below is to be followed. If in case the PADT-II cannot be used in the system, a part of the system still
can follow this outline.
TROUBLESHOOTING CONTENTS
1. Standard Flow of Diagnosis
The troubleshooting sections follow the basic diagnosis flow which is given below. If the diagnosis
flow is different from that given below, or if additional explanation is required, the details of such
differences or additions will also be listed.

00 GENERAL
/ 10 HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
Diagnostic method
T
AF
R
DOIMS000R07002
2. System Operation and Symptom Verification Tests

If verification of the trouble symptoms is difficult, procedures for checking operation and verifying
D
trouble symptoms are shown.

3. Diagnosis Function
Details which are different from those in the “Diagnosis Function” section on the next page are listed.
4. Inspection Chart for Diagnosis Codes
Indicates the inspection procedures corresponding to each diagnosis code (Refer to Section HOW TO
USE THE INSPECTION PROCEDURES).
5. Inspection Procedure for Diagnosis Codes
Indicates the inspection procedures corresponding to each diagnosis code (Refer to Section HOW TO
USE THE INSPECTION PROCEDURES).
7.Inspection Procedure for Trouble Symptoms
Indicates the inspection procedures corresponding to each trouble symptoms classified in the Inspection
Chart for Trouble Symptoms (Refer to Section HOW TO USE THE INSPECTION PROCEDURES).
8. Service Data Reference Table
Inspection items and normal judgement values have been provided in this chart as reference inform-
ation.

GENERAL 00
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS / 11
9. Check at ECU Terminals

Terminal numbers for the ECU connectors, inspection items and standard values have been provided
in this chart as reference information.
10. Inspection Procedures Using an Oscilloscope
When there are inspection procedures using an oscilloscope, these are listed under this section.
DIAGNOSIS FUNCTION
Method of Reading Diagnosis Codes When Using
PADT-II
Connect the PADT-II VCI (Vehicle communication
interface) to the diagnosis connector and take a
reading of the diagnosis codes.
Symbol Description
A Wireless method
B Cable method
CAUTION
Turn Off the ignition switch before connecting
T or disconnecting the PADT-II

Method of Erasing Diagnosis Codes
AF
1. When Using PADT-II
Connect the PADT-II to the diagnosis connect-
or and erase the diagnosis code.
2. When Not Using PADT-II
1. Turn the ignition switch OFF.

2. After disconnecting the battery cable
R
from the battery (-) terminal for 10

seconds or more, reconnect the cable.
DOIQC000R11001 3. After the engine has warmed up, run
D
it at idle for about 15 minutes.

00 GENERAL
HOW TO USE THE INSPECTION PROCEDURES

The causes of a high frequency of problems accuring in electronic circuitry are generally the connectors,
components, the ECU and the harnesses between connectors, in that order. Normally the inspection
procedures will first concentrate in discovering a problem with a connector or a defective component
followed by others in sequence.
T
AF
R
D
DOIMS000R07005
Symbol Description
A Indicates diagnosis code or trouble symptom
B Comments on the diagnosis code or trouble symptom described above
C Probable cause for the trouble symptom
D Indicates/describes instruction to take in analysing trouble symptom
Indicates condition of the result for each instruction; judgement of
E
OK or NG
F Indicates the next instruction to be followed
Indicates detailed inspection procedures (methods) are listed on a
G
separate page; and given here for reference
Harness Inspection
Check for an open or short circuit in the harness between the terminals which were defective according
to the connector measurements. Carry out this inspection while referring to the electrical wiring
manual. Here, “Check harness between power supply and terminal xx” also includes checking for

GENERAL 00
blown fuses. For inspection service points when there is a blown fuse, refer to “ Inspection Service
Points for a Blown Fuse”.
Action Taken After Replacing The ECU
If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection
procedure from the beginning.
CONNECTOR MEASUREMENT SERVICE
POINTS
Turn the ignition switch to OFF when connecting
and disconnecting the connectors, and turn the
ignition switch to ON when measuring if there
are no instructions to the contrary.
If Inspecting With The Connector Connected
(With Circuit In A Condition Of Continuity)
Waterproof connectors
Never insert a test bar from the harness side,
because doing so will reduce the waterproof
performance and result in corrosion.
T Symbol
A
Description
Harness connector
AF
DOIJC000R01014
Ordinary (non-waterproof)
Check by inserting the test bar from the harness
side. Note that if the connector (control unit,
R
etc.) is too small to permit insertion of the test

bar, it should not be forced; use a special tool
(the extra-thin probe in the harness set for
checking) for this purpose.
D
Symbol Description
A Connector
B Test bar
C Extra-thin probe
DOIJC000R01015
If Inspecting With The Connector Disconnected

<When inspect a female pin>
Use the special tool (inspection harness for con-
nector pin contact pressure in the harness set for
inspection).
Symbol Description
A Inspection harness for connect-
or pin contact pressure
The inspection harness for connector pin contact
pressure should be used. The test bar should
never be forcibly inserted, as it may cause a de-
DOIJC000R01016
fective contact.

00 GENERAL
<When inspect a male pin>

Touch the pin directly with the test bar.
CAUTION
At this time, be careful not to short the connect-
or pins with the test bars. Doing so, may damage
the circuits inside the ECU.
DOIJC000R01017
CONNECTOR INSPECTION
VISUAL INSPECTION
• Connector is disconnected or improperly
connected
• Connector pins are pulled out
• Due to harness tension at terminal section
T • Low contact pressure between male and fe-

male terminals
• Low connection pressure due to rusted ter-
AF
minal or foreign matter lodged in terminals.
Check for an open or short circuit in the harness
between the terminals which were defective ac-
cording to the connector measurements. Carry
out this inspection while referring to the electric-
al wiring manual. Here, “Check harness between
R
power supply and terminal xx” also includes

checking for blown fuses. For inspection service
points when there is a blown fuse, refer to “ In-
spection Service Points for a Blown Fuse”.
D
Symbol Description
A Connector disconnected or
improperly connected
B Defective connector contact
C Harness wire breakage at ter-
minal section
D Low contact pressure
DOIJC000R01020

GENERAL 00
CONNECTOR PIN INSPECTION

If the connector pin stopper is damaged, the
terminal connections, (male and female pins) will
not be perfect even if the connector body is
connected, and the pins may pull out of the re-
verse side of the connector. Therefore, gently
pull the harnesses one by one to make sure that
no pins pull out of the connector.
DOIJC000R01022
CONNECTOR ENGAGEMENT INSPECTION

Use the special tool (connector pin connection
pressure inspection harness of the inspection
harness set) to inspect the engagement of the
male pins and female pins. (Pin drawing force :
1 N or more)
T Symbol
A
Description
MB 991219
AF
DOIJC000R01023
INSPECTION SERVICE POINTS FOR A

BLOWN FUSE
R
Remove the fuse and measure the resistance

between the load side of the fuse and the earth.
Set the switches of all circuits which are connec-
ted to this fuse to a condition of continuity. If
D
the resistance is not 0 Ω, there is no short at the

present time, but a momentary short has prob-
ably caused the fuse to blow.
The main causes of a short circuit are as follow
• Harness being clamped by the vehicle body
• Damage to the outer casing of the harness
due to wear or heat.
• Water getting into the connector or circuitry
• Human error (mistakenly shorting a circuit,
etc.)
Symbol Description
A Battery
B Fuse
C Load switch
D Load
E Connector inspection
DOIJC000R01019

00 GENERAL
/ 16 VEHICLE IDENTIFICATION
POINT TO NOTE FOR INTERMITTENT

MALFUNCTIONS
Intermittent malfunctions often occur under
certain conditions, and if these conditions can
be ascertained, determining the cause becomes
simple. In order to ascertain the conditions under
which an intermittent malfunction occurs, first
ask the customer for details about the driving
conditions, weather conditions, frequency of
occurrence and trouble symptoms, and then try
to recreate the trouble symptoms. Next, ascertain
whether the reason why the trouble symptom
occurred under these conditions is due to vibra-
tion, temperature or some other factor. If vibra-
tions is thought to be the cause, carry out the
following checks with the connectors and com-
ponents to confirm whether the trouble symp-
tom occurs.
The objects to be checked are connectors and
T components which are indicated by inspection

procedures or given as probable causes (which
generate diagnosis codes or trouble symptoms).
AF
• Gently shake the connector up, down and to
the left and right.
• Gently shake the wiring harnesses up, down
and to the left and right.
• Gently rock each sensor and relay, etc. by
hand.
R
• Gently shake the wiring harness at suspen-

sions and other moving parts.
NOTE
D
If determining the cause is difficult, recorder

function of the PADT-II can also be used.
DOIJC000R01018
VEHICLE IDENTIFICATION
WCH000VIDEN11006
VEHICLE INFORMATION CODE PLATE

Location
Vehicle information code plate is riveted on the
center pillar RH (driver side) as shown in the illus-
tration.
DOIQC000R12002

GENERAL 00
VEHICLE IDENTIFICATION / 17
Code Plate Description

The plate shown model code, engine model,
transmission model and colour code.
Symbol Description
A VIN CODE
B ENGINE
C TRANS AXLE
D EXTERIOR CODE
E INTERIOR CODE
F OPTION CODE
DOIQC000R11008
G GROSS VEHICLE WEIGHT
H GROSS COMBINATION
WEIGHT
I FRONT AXLE WEIGHT
J REAR AXLE WEIGHT
MODELS
4-DOOR SEDAN
Model code
T
Engine model Transmission Fuel supply sys-
AF
model tem
5MTT200A (2WD
SNBYRMA0
- 5-Speed M/T)
5MTT200A (2WD
SNJYRMA0
S4PH IAFM+ (1597 cm³ (97.45 - 5-Speed M/T)
cu.in)) CVT2 (2WD - 6-
CR6 STBYRMA0 MPI
R
Speed)
CVT2 (2WD - 6-
STJYRMA0
Speed)
D
CVT3 (2WD - 7-
SDHARMA0 S4PH CFE (1561 cm³ (95.25 cu.in))
Speed)
MODEL CODE
1 2 3 4 5 6 7 8 9 10 11
↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
C R 6 S N B Y R M A 0
No. Items Contents

1 Car segment C : Intermediate class
2 Platform R: Persona R
3 Engine size 6 : S4PH IAFM+ (1597 cm³ (97.45 cu.in))
6 : S4PH CFE (1561 cm³ (95.25 cu.in))
4 Body type S : 4–Door sedan
N : 5 – Speed Manual Transmission
5 Transmission type T : 6 – Speed CVT2
D: 7 – Speed CVT3

00 GENERAL
No. Items Contents

B: Low Line
6 Grade of spec J : M - Line
H : H - Line
Y : MPI DOHC IAFM+
7 Engine type
A : MPI DOHC CFE
Steering Wheel Loca- R : Right hand drive
8
tion L : Left hand drive
9 Manufacturer M : PROTON
10 Destination A : Domestic
11 Product life cycle 0 : Roll out (start of lifecycle)
CHASSIS NUMBER
The chassis number is engraved at two location.
Location 1 (under driver seat)
The chassis number is engraved on the front floor
crossmember under driver seat. The chassis
T number can be seen once floor carpet is opened.

NOTE:
AF
Torch light is recommended to be used.
DOIQC000R12003
R
Location 2 (under rear seat cushion, right side)

The chassis number is engraved on the rear floor
at under rear cushion (RHS). The chassis number
D
can be seen once the rear seat cushion (RHS) is

tumbled and the number can be seen on the
floor carpet is opened.
DOIQC000R12004
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
P L 1 C R 6 S N R B F X X X X X X
No. Items Contents

1–3 WMI Malaysia
4 Size C Intermediate class
5 Model Series R Persona R

GENERAL 00
No. Items Contents

6 S4PH IAFM+1597 cm³ (97.45 cu.in)
petrol engine
6 Engine Displacement
6 S4PH CFE1561 cm³ (95.25 cu.in) petrol
engine
7 Body Type S 4–Door sedan
N 5 – Speed Manual Transmission
8 Transmission type T 6 – Speed CVT2
D 7 – Speed CVT3
R Right hand drive
9 Steering Wheel Location
L Left hand drive
10 Production Year B 2011
11 Manufacturer. Plant G Proton city, TG Malim
12–17 Chassis Number — 000001
ENGINE MODEL AND SERIAL NUMBER
1. The engine model number is stamped at the
T
cylinder block as shown in the illustration.
Engine Model Engine Displacement

S4PH 1597 cm³ (97.45 cu.in)
AF
Symbol Description
A Engine model number
B Engine serial number
2. The engine serial number is stamped near
the engine mode number.
R
Engine Serial Number [Example]

NS0001
D
NOTE:
DOIQC000R11006

00 GENERAL
TRANSMISSION MODEL AND SERIAL

NUMBER
Manual transmission
The transmission model number and serial num-
ber engraved are on the transmission case as
Symbol Description
A Transmission model number
B Transmission serial number
NOTE:
T
AF
DOIQC000R11005
Continuous Variable Transmission (CVT)

The transmission number and serial number plate
R
are on the transmission case as shown in the illus-

tration.
Symbol Description
D
A Proton part number

C Supplier part number
NOTE:
DOIQC000R11004

GENERAL 00
MAJOR SPECIFICATIONS / 21
MAJOR SPECIFICATIONS WCH000MSPEC11004
4-DOOR SEDAN
T
AF
R
DOIQC000R11003
D
Items / Model BASE LINE BASE LINE MEDIUM MEDIUM HIGH LINE
(5M/T) (CVT2) LINE (5M/T) LINE (CVT2) (CVT3)
Overall length 1 4543 mm (178.86 in)
Overall width 2 1786 mm (70.31 in)
Overall height 3 1524 mm (60 in)
Wheelbase 4 2650 mm (104.33 in)
Front track 5 1542 mm (60.71 in)
Rear track 6 1542 mm (60.71 in)
Minimum running
ground clearance 7 155 mm (6.1 in) (Front sub-frame)
(Unladen)
Front overhang 8 918 mm (36.14 in)
Rear overhang 9 975 mm (38.39 in)
Weight : 1300 kg 1320 kg 1305 kg 1325 kg 1340 kg
Kerb weight (13000 N, (13200 N, (13050 N, (13250 N, (13400 N,
2866.5 lbs) 2910.6 lbs) 2877.52 lbs) 2921.62 lbs) 2954.7 lbs)

00 GENERAL
/ 22 PRECAUTION BEFORE SERVICE
Items / Model BASE LINE BASE LINE MEDIUM MEDIUM HIGH LINE
(5M/T) (CVT2) LINE (5M/T) LINE (CVT2) (CVT3)
Gross vehicle 1660 kg 1680 kg 1665 kg 1685 kg 1700 kg
weight (16600 N, (16800 N, (16650 N, (16850 N, (17000 N,
3660.3 lbs) 3704.4 lbs) 3671.33 lbs) 3715.42 lbs) 3748.5 lbs)
Max. axle weight
Front 950 kg (9500 N, 2094.75 lbs)
Rear 900 kg (9000 N, 1984.5 lbs)
Seating capacity 5
Engine
S4PH IAFM+ S4PH CFE
Model No.
Total displacement 1561 cm³
1597 cm³ (97.45 cu.in)
(95.25 cu.in)
Transmission
Model 5MTT200A CVT2 5MTT200A CVT2 CVT3
Type 5 – Speed
5 – Speed M/T 6 – Speed 6 – Speed 7 – Speed
M/T
T
Fuel supply system Electronic controlled multipoint fuel injection
PRECAUTION BEFORE SERVICE WCH000BSERV11001

AF
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER
1. Items to follow when servicing SRS
1. Be sure to read GROUP 52B - Supplemental Restraint System (SRS).
For safe operations, please follow the directions and heed all warnings.
2. Always use the designated special tools and test equipment.
R
3. Wait at least 5 minutes after disconnecting the battery cable before doing any further work.
The SRS system is designated to retain enough voltage to deploy the air bag deployment if
work is done the SRS system immediately after the battery cable is disconnected.
4. Never attempt to disassemble or repair the SRS components. (SRS air bag control unit, air bag
D
module and clock spring.) If faulty, replace it.

5. Warning labels must be needed when servicing and handling SRS components. Warning labels
are located in the following locations.
• Sun visor
• SRS air bag control unit
• Front driver's air bag module
• Front passenger's air bag module1
• Seat belt pre-tensioner
• Clock spring
6. Store components removed from the SRS in a clean and dry place.
The air bag module should be store on a flat surface and placed so that the pad surface is facing
upwards.
7. Be sure to deploy the air bag before disposing of air bag module or disposing of a vehicle
equipped with an air bag. (Refer to GROUP 52B - Air Bag Module Disposal Procedures.)
8. Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure
that the system functions properly.
2. Observe the following when carrying out operations on place where SRS components are installed,
including operations not directly related to the SRS air bag.
1. When removing or installing parts do not allow any impact or shock to the SRS components.
NOTE:
1: If fitted

GENERAL 00
PRECAUTION BEFORE SERVICE / 23
2. SRS components should not be subjected to heat over 85 °C (185 °F),

so remove the SRS components before drying or baking the vehicle after painting. After rein-
stalling them, check the SRS warning lamp operation to make sure that the system functions
properly.
3. After re-installing them, check the SRS warning lamp operation to make sure that the system
functions properly.
SERVICING THE ELECTRICAL SYSTEM
Before replacing a component related to the
electrical system and before undertaking any
repair procedures involving the electrical system,
be sure to first disconnect the negative (-) cable
from the battery in order to avoid damage
caused by short-circuiting.
CAUTION
Before connecting or disconnecting the negative
(-) cable, be sure to turn off the ignition switch
and lighting switch. (If this is not done, there is
DOIIC000R9019 the possibility of semiconductor parts being
damaged ).
APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS
T
If oil grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor.
AF
Cover the oxygen with a protective cover when applying anti-corrosion agents and undercoats.
PRE-INSPECTION CONDITION
“Pre-inspection condition” refer to the condition that the vehicle must be in before proper engine
inspection can be carried out. If you see the words “Set the vehicle to the pre condition”. in this
manual, it means to set the vehicle to the following condition.
R
• Engine Coolant temperature : 80 - 90 °C (176 - 194 °F)

• Lamps. electric cooling fan and all accessories : OFF
• M/T : Neutral
D
• A/T : P range
VEHICLE WASHING
If high-pressure car-washing equipment or steam
car-washing equipment is used to wash the
vehicle, be sure to note the following informa-
tion in order to avoid damage to plastic compon-
ents, etc.
1. Spray nozzle distance : Approx. 40 cm (15.75
in) or more
2. Spray pressure : 39000 kPa (5548.14 psi,
11773.32 in.Hg) or less
3. Spray temperature : 82 °C (179.6 °F) or less
DOIIC000R9020 4. Time to connected spray to one point: within
30 sec.

00 GENERAL
PROTON ADVANCE DIAGNOSTIC TOOL–II

(PADT-II)
Refer to PADT-II user manual for instructions on
handling the PADT-II.
DOIQC000R11002
Connect the PADT-II to the diagnosis connector

as shown in the illustration.
Symbol Description
A Wireless method
B Cable method
T CAUTION
Connection and disconnection of the PADT-II
should always be made with the ignition switch
AF
in the OFF position.
R
D
DOIQC000R11001
IN ORDER TO PREVENT VEHICLE FROM FIRE

“Improper installation of electrical or fuel related parts could cause fire. In order to retain the high
quality and safety of the vehicle, it is important that any accessories that may be fitted or modifica-
tion/repairs that may carried out which involved the electrical or fuel systems, MUST be carried out
in accordance with PROTON information/instruction.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from skin,
leading to dryness, irritation and dermatitis. In addition , used engine oil contains potentially harmful
contamination which may cause skin cancer, Adequate means of skin protection and washing facilities
must be provided.

GENERAL 00
Recommended and 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 system for handling used engine
oil and by decreasing components, where practicable, before handling them.
Other Precaution
• Avoid prolonged and repeated contact with oil, particularly used engine oils.
• Wear protective clothing, including impervious gloves practicable.
• Avoid contamination clothes, particularly underpants, with oil.
• Do not put oily rag in pockets, the use of overalls without pockets will avoid this
• Do not wear heavily soiled clothing and impregnated foot-wear. Overalls must be clean regularly
and kept separately from personnel clothing.
• Where there is risk of eye contact, eye protection should be worn, for example, chemical goggles
• 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 preparation containing
• Do not used petrol, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.
• Use barrier cream, applying them before each work period, to help the removal of oil from the
•
skin after work.
T
If skin disorder develop, obtain medical advise without delay.
AF
R
D

00 GENERAL
/ 26 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH

PRE-TENSIONER WCH000SRSYS11001
The SRS (Supplemental Restraint System) air bag is a system that is effective with the seat belt fastened,
and it is designed as a supplemental system of the seat belt. The air bag inflates upon a frontal collision
or a side collision to protect the passengers. The SRS consist of two air bag modules, SRS air bag control
unit (SRS-ECU), two front impact sensors, SRS warning lamp, clock spring, and seat belt pre-tensioner.
Front air bags are located in the centre of the steering wheel and above the glove box. The SRS-ECU
under the front floor console monitors the system and has a front air bag safing G-sensor, front air
bag analogue G-sensor and a side (curtain) air bag analogue G-sensor. The front impact sensor is in-
stalled on the front end upper bar in the engine room and contains an analogue G-sensor and a mi-
crocomputer. The warning lamp on the instrument panel indicates the operational status of the SRS.
The clock spring is installed in the steering column. The seat belt pre-tensioner is built into the driver’s
and passenger’s front seat belt retractor. Only authorized service personnel should do work on or
around the SRS components. Those service personnel should read this manual carefully before starting
any such work.
T
AF
R
D

GENERAL 00
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER / 27
T
AF
R
D
DOIQC000R12008

00 GENERAL
/ 28 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER
SEAT BELT WITH PRE-TENSIONER

The seat belts with pre-tensioners are installed on both center pillars.
The pre-tensioner, which is controlled by the SRS-ECU, works simultaneously with the SRS air bag in
a head-on collision. When triggered, the SRS-ECU sends a squib igniting signal to the gas generator.
Generated gas moves the rotor to take up seat belt slack. This prevents a passenger from moving
forwards excessively. After this, the ELR works to inhibit the seat belt.
CAUTION
Never disassemble or give an impact to the seat belt with pre-tensioner.
T
AF
R
D

GENERAL 00
SUPPORT LOCATIONS FOR LIFFTING AND JACKING / 29
SUPPORT LOCATIONS FOR LIFFTING AND JACKING WCH000SLIFT11001
CAUTION
Do not support the vehicle at locations other than specified supporting points. If do so, this will cause
damaged and etc.
SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS
T
AF
R
D
DOIQC000R12005
Symbol Description
A Notch
CAUTION
Never support any point other than specified one, or it will be deformed.

00 GENERAL
/ 30 SUPPORT LOCATIONS FOR LIFFTING AND JACKING
SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT

CAUTION
When service procedures require removing rear suspension, spare tyre and rear bumper, place addi-
tional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of center of gravity
changes.
T
AF
R
D
DOIQC000R12006
Symbol Description
A Notch
B Double-post lift
C Single-post lift

GENERAL 00
SUPPORT LOCATIONS FOR LIFFTING AND JACKING / 31
SUPPORT POSITION AND SUPPORT

METHOD FOR AN H-BAR LIFT
Symbol Description
A H-bar lift
CAUTION
When service procedures require removing rear
suspension, fuel tank, spare tyre and rear
bumper, place additional weight on rear end of
vehicle or anchor vehicle to hoist to prevent
tipping of center of gravity changes.
DOIQC000R12007 When H-bar lift is used to lift up vehicles, use of
metallic attachment attached to the H-bar lift
may cause damage to the suspension arm etc.
Therefore, lift up the vehicle by the following
procedure.
1. Place the vehicle on the H-bar lift (same dir-
ection).
T Symbol
A
B
Description
Chassis-support position
Attachment
AF
C H-bar lift
D Side sill
'A-A' Section
2. Place attachments on the H-bar lift at the
designated chassis-support positions. When
R
making the attachments refer to the section

concerning making them.
CAUTION
D
If support at any location other than the

designated positions, the body or suspension
might be deformed or otherwise damaged,
so care should be taken to support only at
the correct (designated) position.
3. Raise the H-bar lift to the height at which
the vehicle is slightly raised and check the
vehicle is correctly and sufficiently secured,
then raise the vehicle.
DOIIC000R9030

00 GENERAL
/ 32 TIGHTENING TORQUE
PREPARATION OF “ATTACHMENTS”
1. Prepared the blocks (wooden) and nails as
shown in the figure.
Items Dimension Quant-

ity
Block 90 mm (3.54 in) x95 mm 2
(A) (3.74 in) x 1800 mm
(70.87 in)
Block (B) 60 mm (2.36 in) x 100 4
mm (3.94 in) x 95 mm
(3.74 in)
Block (C) 140 mm (5.51 in) x 40 8
mm (1.57 in) x 95 mm
(3.74 in)
Nail (D) 70 mm (2.76 in) or more 32
CAUTION
The wood selected for the blocks must be
hard.
T 2. For the (B) blocks and (C) blocks, use a saw

and chisel or similar tool to make grooves of
the dimension shown in the figure.
AF
3. Make four “ATTACHMENTS” such as shown
in the figure nailing (B) and (C) blocks so that
DOIIP000R9013 each (B) blocks is sandwiches between (C)
blocks.
4. Finished wooden attachment.
R
Symbol Description
(A) Moveable according to
chassis width
D
DOIIP000R9014
TIGHTENING TORQUE WCH000TTORQ11001
Each torque value in the table is a standard value for tightening under the following conditions.
1. Bolts, nuts and washes are all made of steel and plated with zinc.
2. The treads and bearing surface of bolts and nuts are all in dry condition.
The values in the table are not applicable:
1. If toothed washes are inserted.
2. If plastic parts are fastened.
3. If bolts are tightened to plastic or die-cast insert nuts.
4. If self-tapping screws or self-locking nuts are used.

GENERAL 00
TIGHTENING TORQUE / 33
Standard bolt and nut tightening torque

Tread size Torque
Bolt nominal
Pitch Head mark “4” Head mark“7”
diameter
M5 0.8 mm (0.031 in) 0.25 kgm (2.5 Nm, 1.81 0.49 kgm (4.9 Nm, 3.54 ft.lbs)
ft.lbs)
ft.lbs)
M8 1.25 mm (0.049 in) 1.2 kgm (12 Nm, 8.68 ft.lbs) 2.2 kgm (22 Nm, 15.91 ft.lbs)
M10 1.25 mm (0.049 in) 2.4 kgm (24 Nm, 17.36 4.4 kgm (44 Nm, 31.83 ft.lbs)
ft.lbs)
ft.lbs)
ft.lbs)
M16 1.5 mm (0.059 in) 11.1 kgm (111 Nm, 80.29 20.6 kgm (206 Nm, 149 ft.lbs)
ft.lbs)
T
M18 1.5 mm (0.059 in) 16.7 kgm (167 Nm, 120.79 30.4 kgm (304 Nm, 219.88
ft.lbs) ft.lbs)
M20 1.5 mm (0.059 in) 22.6 kgm (226 Nm, 163.47 41.2 kgm (412 Nm, 298 ft.lbs)
AF
ft.lbs)
ft.lbs) ft.lbs)
ft.lbs) ft.lbs)
Flange bolt and nut tightening torque
R
Tread size Torque

Bolt nominal
Pitch Head mark “4” Head mark “7”
D
diameter
ft.lbs)
M8 1.25 mm (0.049 in) 1.3 kgm (13 Nm, 9.4 ft.lbs) 2.4 kgm (24 Nm, 17.36 ft.lbs)
ft.lbs)
ft.lbs)
ft.lbs)
ft.lbs)

00 GENERAL
/ 34 TIGHTENING TORQUE
NOTE
T
AF
R
D

ENGINE <CFE> 11A
Content /1
11A ENGINE <CFE>

GENERAL SPECIFICATIONS .......................................................... 11A/4
SPECIFICATIONS ..................................................................... 11A/4
SPECIAL TOOLS ........................................................................ 11A/4

TOOLS ................................................................................. 11A/4
PROTON ADVANCE DIAGNOSTIC TOOL PADT-II COMMUNICATION ........ 11A/6

SPECIAL FUNCTION DESCRIPTION ............................................... 11A/6
PADT-II PREPARATION .............................................................. 11A/7
SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/9
SPECIAL FUNCTION ................................................................. 11A/10
VEHICLE CONFIGURATION- FIRST INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/10
VARIANT CODING- AIR CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/15
VARIANT CODING- AUTO CRUISE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/17
MODEL NAME READ AND WRITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/19
RESET VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/21
FEAD BELT DRIVE AND TV DAMPER PULLEY .................................... 11A/24

REMOVAL AND INSTALLATION ................................................... 11A/24
FEAD BELT DRIVE ......................................................................

REMOVAL SERVICE POINTS .......................................................
INSTALLATION SERVICE POINTS ..................................................
T 11A/26
11A/26
11A/26
AF
TV DAMPER PULLEY .................................................................. 11A/28
REMOVAL SERVICE POINT ......................................................... 11A/28
INSTALLATION SERVICE POINT ................................................... 11A/28
ALTERNATOR ........................................................................... 11A/30

R

INSTALLATION SERVICE POINTS .................................................. 11A/31
TIMING BELT ........................................................................... 11A/32

D

REMOVAL SERVICE POINTS ....................................................... 11A/34
INSTALLATION SERVICE POINTS ................................................. 11A/35
TIMING BELT / TIMING BELT TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/35
CAMSHAFT AND CAMSHAFT OIL SEAL ........................................... 11A/42

LUBRICATION POINTS .............................................................. 11A/44
CAMSHAFT AND TAPPET ........................................................... 11A/46

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/46
INSPECTION .......................................................................... 11A/60
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/60
CYLINDER HEAD GASKET ........................................................... 11A/61


11A ENGINE <CFE>
/2 Content
CRANKSHAFT OIL SEAL .............................................................. 11A/67

FLYWHEEL PART MARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/70
OIL PAN ................................................................................. 11A/72

ENGINE ASSEMBLY ................................................................... 11A/78

ON-VEHICLE SERVICE ................................................................. 11A/81

COMPRESSION PRESSURE CHECK ................................................ 11A/81
T
AF
R
D

ENGINE <CFE> 11A
Content /3
NOTE
T
AF
R
D

11A ENGINE <CFE>
/4 GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS WCH11ASPECS12001
SPECIFICATIONS
Specifications
Items
Campro CFE (Charged Fuel Efficient)
Total displacement 1561 cm³ (95.25 cu.in)
Bore x stroke 76.0 x 86.0 mm (2.99 x 3.39 in)
Direction of Rotation Clockwise (From front : SAE)
Number of cylinders 4
Valve train DOHC 16V
Combustion chamber Pentroof type
Firing order 1–3–4–2
Compression ratio 10:01
Tappet Hydraulic latch adjuster
Intake 8
Number of valve
Exhaust 8
Maximum output 103 kW(138 hp) @ 5000 rpm
Maximum torque
Battery
T 205 Nm @ 2000 ~ 4000 rpm
55D23L
AF
Electrical System Alternator 12V – 90A
Starter max-output 12V – 1.2kW
Type Electronic controlled multipoint fuel injection
Fuel system
Fuel Ron 97
Lubrication system Pressure feed, full-flow filtration
R
Engine oil capacity 3.75 Litre

Oil pump type Trochoid type
Fuel system Electronic controlled multipoint fuel injection
D
Water pump type Centrifugal impeller type

Cooling system Water-cooled forced circulation
SPECIAL TOOLS WCH11ASTOOL12002
TOOLS
Tool Number Name Use
EZT0047 PADT-II VCI Kits For vehicle diagnosis, ECU,
Flashing, vehicle measurement
and troubleshooting
DOIMC35BR11039

ENGINE <CFE> 11A
SPECIAL TOOLS /5

EZT 0044 Flywheel Stopper To lock flywheel
DOIME11AR11051
MD990767 End yoke holder Holding the camshaft sprocket
DOIIC11AR9003
MD998719 or Crankshaft pulley Holding the camshaft sprocket

MD998754 holder pin
T
AF
DOIIC11AR9004
MD998718 Crankshaft rear oil seal Press in of the crankshaft rear

installer oil seal
R
DOIIC11AR9008
A: MD998304 A: Crankshaft front oil Press-in of the crankshaft

B: MD998305 seal installer front oil seal
D
B: Crankshaft front oil

seal guide
DOIIC11AR9009
MB991653 Cylinder head bolt Cylinder head bolt removal

wrench and installation
DOIIC11AR9010
MD998054 Oil pressure switch Removal and installation of

wrench oil pressure switch
DOIIE11AR9004

11A ENGINE <CFE>
/6 PROTON ADVANCE DIAGNOSTIC TOOL PADT-II COMMUNICATION

MOT 591–04 Angle gauge To get accurate angle during
00 00 059 104 installing cylinder head bolt
and TV damper bolt
DOIGC11AR03151
EZT 0003 TV damper stopper To lock TV damper from turn-

ing
DOIGE11AR03105
EZT 0004 Camshaft sprocket To prevent camshaft sprocket

stopper from turning during installing
timing belt
DOIGE11AR03134
T
AF
EZT 0006 Camshaft oil seal in- Installation of camshaft oil
staller seal
R
DOIGE11AR03155
EZT 0007 TV damper bolt To turn crankshaft sprocket

dummy during aligning timing belt
D
DOIGE11AR03146
PROTON ADVANCE DIAGNOSTIC TOOL PADT-II COMMUNICATION

WCH11ASPROC12001
SPECIAL FUNCTION DESCRIPTION

Carry out special function procedure using PADT-II according to the instruction below;
Special Function Purpose Time of execution

Vehicle configuration To initialize between the en- When loading new software to ECU
- First initialization gine ECU and throttle body or replace new engine
or replace new throttle body
or replace new engine ECU
Variant coding To set vehicle variant When replace new engine ECU.
- Air condition
- Auto cruise setting

ENGINE <CFE> 11A
PROTON ADVANCE DIAGNOSTIC TOOL PADT-II COMMUNICATION /7

Immobilizer coding To code key with immobilizer When replace new engine ECU or when
- Key ID register replace news sets of keys.
- Clear key
Model name read and write To set the vehicle code to en- When replace new engine ECU.
gine ECU
Reset values To reset engine ECU software When loading new software to ECU
to default setting. or replace new engine
PADT-II PREPARATION
1. Connect PADT-II to diagnostic connector
(The position of the diagnostic connector
varies between models).
Symbol Description
A PADT-II vehicle communic-
ation interface (VCI)
T B
C
OBD-II cable
USB cable
2. Switch the ignition key to “ON” position.
AF
DOIMC35BR11048
R
D
DOINC11AR11026

11A ENGINE <CFE>
3. Select the vehicle model to be diagnosed in

PADT-II menu.
Symbol Description
A Model selection ‘ Exora Bold’
T
AF
R
D
DOINC11AR11027
4. PADT-II will display the available system of

the vehicle selection.

ENGINE <CFE> 11A
T
AF
DOINC11AR11028
R
5. Click on the ID icon to view detail of the

available system.
Symbol Description
D
B ID icon
SECURITY
For security purposes, the Special Function menu
will require password to be accessed. Please
contact Proton call centre to obtain security code.
DOIMC11AR11071

11A ENGINE <CFE>
/ 10 PROTON ADVANCE DIAGNOSTIC TOOL PADT-II COMMUNICATION
SPECIAL FUNCTION WCH11ASPROC12002
VEHICLE CONFIGURATION- FIRST INITIALIZATION
T
AF
R
DOINC11AR11041
1. Set up the PADT-II program (refer to 11A/6

D
)
Then select the module selection.
Symbol Description
A Test selection ‘Active Tests’
B Subsystem selection ‘Select
Subsystem’
C System selection ‘EASY-
U_IAFM+/CFE’

ENGINE <CFE> 11A
PROTON ADVANCE DIAGNOSTIC TOOL PADT-II COMMUNICATION / 11
T
AF
DOINC11AR11029
R
2. Select the special function menu to start the

vehicle configuration.
Symbol Description
D
D Function selection ‘Special

Functions’
E Test selection ‘First Initializa-
tion’
3. Ensure that the engine is stopped and the
ignition at ON position to start the proced-
ure.
DOIMC11AR11025

11A ENGINE <CFE>
4. Switch the ignition key to OFF position. Then

press next to continue.
DOIMC11AR11026
5. Please wait while the system is being initial-

ized.
T
AF
DOIMC11AR11027
6. Switch the ignition to ON position. Then

R
D
DOIMC11AR11028

ized.
DOIMC11AR11030

ENGINE <CFE> 11A
8. Switch the ignition to OFF position. Then

DOIMC11AR11031

ized.
T
AF
DOIMC11AR11032
10. Switch the ignition to ON position. Then

R
D
DOIMC11AR11033
11. Check the throttle body adaptation status is

‘DONE’.
Press next to continue.
DOIMC11AR11034

11A ENGINE <CFE>
12. The initialization process is completed.

Click exit button to return to main menu.
DOIMC11AR11035
T
AF
R
D

ENGINE <CFE> 11A
VARIANT CODING- AIR CONDITION WCH11ASPROC12003
T
AF
R
DOINC11AR11030
1. Run the PADT-II program. Refer to 11A/6 .

Then select the module selection to start the
D
diagnosis activity.
Symbol Description
A Test selection ‘Active Test’
B Diagnosis selection ‘Special
Functions’
C Coding selection ‘Air Condition’
2. Read the precondition instruction carefully
before proceeding to the next step.
Ensure that the engine is stopped and the
ignition at ON position before starting the
procedure.
Press next button to continue.
DOIMC11AR11037

11A ENGINE <CFE>
3. Check the current status, and use the drop

down menu to change the status.
Then press next to continue.
DOIMC11AR11038
4. Reconfirm that the status has been changed.

Then press exit to return to main menu.
T
AF
DOIMC11AR11039
R
D

ENGINE <CFE> 11A
VARIANT CODING- AUTO CRUISE SETTING
T
AF
R
DOINC11AR11031

D
diagnosis activity.
Symbol Description
Functions’
C Coding selection ‘Auto Cruise
Setting’

11A ENGINE <CFE>

procedure.
DOIMC11AR11041

down menu to change status.
T
AF
DOIMC11AR11042

R
D
DOIMC11AR11043

ENGINE <CFE> 11A
MODEL NAME READ AND WRITE WCH11ASPROC12004
T
AF
R
DOINC11AR11034

)
D
Symbol Description
Functions’
C Function selection ‘Model Name
Read and Write’

11A ENGINE <CFE>

procedure.
DOIMC11AR11058
3. Key in the new model name in the text box

using capital letters.
T
AF
DOIMC11AR11060

ignition at ON position.
R
D
DOIMC11AR11061
5. Check that the model name is correct.

Press exit to return to main menu.
DOIMC11AR11062

ENGINE <CFE> 11A
RESET VALUES
T
AF
R
DOINC11AR11035

)
D
Symbol Description
Functions’
C Function selection ‘Reset Func-
tion’

11A ENGINE <CFE>

procedure.
DOIMC11AR11064
3. Select ‘Reset Oxygen Control Adaptation’.

T
AF
DOINC11AR11037
4. The reset oxygen control adaptation is suc-

cessful.
Then select ‘Reset Throttle Adaptation’ and
R

D
DOINC11AR11038
5. The reset throttle adaptation is successful.

Then select ‘Reset Torque Loss Adaptation
and press next to continue.
DOINC11AR11036

ENGINE <CFE> 11A
6. Please wait while the system is being reset.

Reconfirm that value status must be ‘0%’.
DOIMC11AR11068
7. The process is finished.

T
AF
DOIMC11AR11070
R
D

11A ENGINE <CFE>
/ 24 FEAD BELT DRIVE AND TV DAMPER PULLEY
FEAD BELT DRIVE AND TV DAMPER PULLEY WCH11ASASSY12001
REMOVAL AND INSTALLATION
T
AF
R
DOINC11AR11024
D
Pre-removal and Post-installation Operation

• Under Cover Removal and Installation (Refer to GROUP 051 — Lower Cover)
Removal steps :
1. Tensioner bolt
2. Tensioner bolt
3. Tensioner
4. FEAD belt
5. TV damper bolt
6. TV damper pulley
T1 : 4.8-5.2 kgm (48-52 Nm, 34.72-37.61 ft.lbs)
T2 : 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
T3 : 3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 120°± 4°

ENGINE <CFE> 11A
FEAD BELT DRIVE AND TV DAMPER PULLEY / 25
T
AF
DOIGC11AR03021
R
Fead belt route

1. Tensioner Accessory Drive pulley
2. TV damper pulley
D
3. Air-cond Compressor pulley

4. Power steering pump pulley
5. Water pump pulley — upper side
6. Alternator pulley
7. Water pump pulley — lower side

11A ENGINE <CFE>
/ 26 FEAD BELT DRIVE
FEAD BELT DRIVE WCH11ASPROC12021
REMOVAL SERVICE POINTS

FEAD BELT REMOVAL
1. Insert ratchet into square hole on tensioner
arm.
Symbol Description
A Ratchet
DOIGC11AR03025
2. Push the ratchet toward engine intake side

and pull out the fead belt from the alternat-
or.
3. Loosen the tensioner half way
4. Remove the fead belt between the slot of
the loosed tensioner.
T Symbol
A Ratchet
Description
AF
DOIGC11AR03026
INSTALLATION SERVICE POINTS

FEAD BELT INSTALLATION
R
1. Ensure drive tensioner is highly loosen.

2. Slot in fead belt in position through the
space between the tensioner and the cover.
D
3. Tighten drive tensioner bolt to the specified

torque.
Standard value torque :
Symbol Description
4.8-5.2 kgm (48-52 Nm, 34.72-
DOIGC11AR03027 T1
37.61 ft.lbs)
2.2-2.6 kgm (22-26 Nm, 15.91-
T2
18.81 ft.lbs)

ENGINE <CFE> 11A
FEAD BELT DRIVE / 27
4. Wrap the fead belt around the tensioner

roller nicely.
NOTE
Make sure the word “MITSUBOSHI” on the
belt is facing outward.
Symbol Description
1 Fead belt
DOIGC11AR03028

arm.
Symbol Description
A Ratchet
T
AF
DOIGC11AR03029
6. Wrap the fead belt around the pulleys anti-

clockwise in the sequence of 1 ⇒ 2 ⇒ 3 ⇒ 4
R
Symbol Description
A Ratchet
1 TV damper
D
2 Compressor pulley
3 Power steering pulley
4 Water pump pulley
DOIGC11AR03030
7. While ensuring no slack, push the ratchet (A)

anticlockwise to loosen the tensioner and
completed the belt installation around altern-
ator pulley (5) and water pump pulley (6).
Release the tensioner in position. Check and
adjust to ensure belt in correct position.
Symbol Description
A Ratchet
5 Alternator pulley
6 Water pump pulley
DOIGC11AR03031

11A ENGINE <CFE>
/ 28 TV DAMPER PULLEY
TV DAMPER PULLEY WCH11ASPROC12019
REMOVAL SERVICE POINT

TV DAMPER BOLT REMOVAL
1. Use the special tool TV damper stopper to
hold the TV damper and then loosen the TV
damper bolts.
Symbol Description
A TV damper stopper
B TV damper bolt
C TV damper pulley
D Dowel
E Crankshaft
F Sprocket crankshaft
T
AF
DOIGC11AR03089
INSTALLATION SERVICE POINT

TV DAMPER BOLT INSTALLATION
R
1. Install the TV damper, use the special tool

TV damper stopper to hold the TV damper
and then tighten the TV damper bolt.
D
Symbol Description
A TV damper stopper
B TV damper bolt
C TV damper pulley
D Dowel
E Crankshaft
DOIGC11AR03089

ENGINE <CFE> 11A
TV DAMPER PULLEY / 29
2. Used the special tool angle gauge to torque

the tv damper bolt at the torque value as
specified.
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm,
1.45 ft.lbs) + 120° ± 4°
Symbol Description
G TV damper pulley
H Angle gauge MOT
591–04
DOIGC11AR03166 I TV damper stopper
J Ratchet
T
AF
R
D

11A ENGINE <CFE>
/ 30 ALTERNATOR
ALTERNATOR WCH11ASASSY12015
T
AF
R
DOINC11AR11001
D

• Fead Belt Removal And Installation (Refer to 11A/24 )
• Splash Shield Rh Removal And Installation (Refer to GROUP 042 – Body)
Removal steps :
1. Tensioner assy drive pulley
2. Fead belt
3. Alternator
T1: 2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs)
T3: 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)
T4: 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)

ENGINE <CFE> 11A
ALTERNATOR / 31

ALTERNATOR INSTALLATION
1. Install alternator with special bolt together
with nut to front cover assy. Pre-tighten the
bolts 2 ~ 3 times and lift up alternator to the
correct position.
2. Tighten the upper bolt to the specified
torque.
Specified torque T1 :
2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.2 kgm (2
DOINC11AR11009
Nm, 1.45 ft.lbs)
Symbol Description
A Upper bolt
B Special bolt
3. Tighten alternator nut to the specified
torque.
T 3.5 kgm (35 Nm, 25.32 ft.lbs) ± 0.2 kgm (2

Nm, 1.45 ft.lbs)
AF
Symbol Description
C Nut
R
DOINC11AR11010
D

11A ENGINE <CFE>
/ 32 TIMING BELT
TIMING BELT WCH11ASASSY12004
T
AF
R
DOINC11AR11012
D

• Disconnect Battery
• Lower Cover Removal and Installation (Refer to GROUP 051)
• Engine Mounting Removal and Installation (Refer to GROUP 032)
• Fead Belt Drive / TV Damper Removal and Installation (Refer to 11A/24 )
• Support engine with crocodile jack
Removal steps :
1. Belt cover lower
2. TV damper pulley
3. Water pump pulley
4. Belt cover top
5. Engine Mounting Bracket
6. Timing belt tensioner
7. Timing belt
8. Crankshaft sprocket

ENGINE <CFE> 11A
TIMING BELT / 33
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 : 2.5 kgm (25 Nm, 18.08 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)
T
AF
R
D

11A ENGINE <CFE>
/ 34 TIMING BELT
REMOVAL SERVICE POINTS WCH11ASPROC12007
TIMING BELT / TIMING BELT TENSIONER

REMOVAL
1. Align camshaft sprocket timing marks ‘‘A’’
to features on cam cover ‘‘B’’ with the aid of
the cam sprocket alignment tool.
Symbol Description
A Camshaft sprocket timing marks
B Cam cover
C Align dowel
D Front case
T
AF
DOINC11AR11013
2. Align crankshaft to 90° ATDC (align dowel

’C’’ to one o’clock feature on front case’’D’’),
by using the special tool together with TV
R
damper bolt, turn the crankshaft sprocket

until get the actual align.
Symbol Description
D
C Align dowel
D Front case mark
E TV damper bolt
F Special tool
DOINC11AR11014

ENGINE <CFE> 11A
TIMING BELT / 35
3. ‘‘STOP’’ the camshaft sprocket from turning

by inserting the special tool in between.
Symbol Description
A Special tool (EZT004)
DOINE11AR11155
4. If the timing belt is to be reused, chalk an

arrow on the belt to indicate the direction
of rotation before removing it. This will en-
sure the timing belt is fitted correctly when
reused.
T
AF
DOINE11AR11023
5. Remove the timing belt tensioner, then pro-

ceed to remove the timing belt.
CAUTION
R
In order to remove the tensioner bolt, make

sure to use the correct single type socket box
because it can prevent the head bolt from
D
damage and wear
Symbol Description
A Single type socket box
B Ratchet
DOINE11AR11021 C Timing Belt Tensioner

WCH11ASPROC12008

INSTALLATION
1. Align camshaft sprocket timing marks (B)
with cam cover marks (A) and lock using
special tool (C) as shown in illustration.
NOTE :
Ensure that crankshaft is in safe position (90°
ATDC) for cylinder no.1.
DOINE11AR11027

11A ENGINE <CFE>
/ 36 TIMING BELT
Symbol Description
A Sprocket marks
B Cam cover marks
C Special tool
2. By using the special tool (EZT0007) align the
crankshaft sprocket to 90° ATDC (dowel pin)
“C” is aligned to “D” at one o'clock feature
on front case).
Symbol Description
C Crankshaft sprocket dowel
pin
D Front case marking
E TV damper bolt
DOIGE11AR03024
3. Fit tensioner bearing (A) by putting the foot

into the core plug (B) indent and ensuring
T the allen key socket is positioned opposite

the foot as shown in illustration.
4. Then tighten tensioner bolt (C) by hand.
AF
Symbol Description
A Tensioner bearing
B core plug
C Tensioner bolt
R
DOINE11AR11058
5. Before installing the reused timing belt,

D
make sure the arrow mark on top of the

timing belt is facing to the right direction.
DOIGE11AR03177

ENGINE <CFE> 11A
TIMING BELT / 37
6. Firstly, fit timing belt halfway on to crank-

shaft sprocket and cam sprockets. Then fit
timing belt around tensioner pulley and push
belt fully onto all sprockets and pulley as
shown in illustration.
Caution:
Make sure (No slack along span 1 [S1] and
span 2 [S2] area.)
T
AF
DOINE11AR11051
7. Turn the tensioner clockwise until pointer

indicator is exactly over the right hand side
edge of indicator notch (refer view B).
R
Tighten tensioner bolt whilst holding the al-

len key in place.
Specified torque :
D
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2

Nm, 1.45 ft.lbs)
DOINE11AR11053

11A ENGINE <CFE>
/ 38 TIMING BELT
8. By using the special tool (EZT0007) with TV

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

position in the centre of the notch scale, the
belt is properly tensioner and task is com-
plete (refer view C).
T
AF
R
D
DOINE11AR11052

ENGINE <CFE> 11A
TIMING BELT / 39
10. If the indicator does not stop within the

nominal position, insert the allen key and
retain the installation shaft’s position on the
while loosening tensioner bolt with torque
wrench. Then using allen key slowly rotate
the installation shaft anti-clockwise until in-
dicator moves to free arm position as shown
on (view D).
T
AF
DOINE11AR11055
11. Rotate tensioner bearing (1) clockwise until

the pointer is positioned in the centre of the
notch scale as shown on (view C)
R
12. Retighten tensioner bolt whilst holding the

allen key in place.
Specified torque :
D
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2

Nm, 1.45 ft.lbs)
DOINE11AR11056

11A ENGINE <CFE>
/ 40 TIMING BELT
13. By using the special tool (EZT 0007) with TV

damper bolt, rotate the crankshaft 720º until
it reach to safe point (90º ATDC). Ensure the
crankshaft dowel pin marking allign back to
front case.
14. CAUTION :
position.
NOTE :
(1) Camshaft sprocket timing marks (A) are
aligned by cam cover timing marks (B).
(2) Crankshaft sprocket dowel pin (C) is
aligned with front case marks (D).
Symbol Description
A Camshaft sprocket timing
marks
B Cam cover marks
pin
T D Front case mark

AF
DOINE11AR11057
15. If the indicator stops within the nominal po-

sition in the centre of the notch scale, the
belt is properly tensioned and the task is
R
complete. If the indicator does not stop in

the middle of the notch scale, then repeat
steps (10 until 14).
D
DOINE11AR11052

ENGINE <CFE> 11A
TIMING BELT / 41
16. After checking the timing belt tension, insert

again the special tool (A) in between of two
camshaft sprockets in order to make sure the
camshaft sprocket “STOP” from turning.
Symbol Description
A Special tool (EZT0007)
DOINE11AR11155
17. Then, turn TV damper bolt anticlockwise to

loose TV damper bolt and special tool.
Remove TV damper bolt and special tool be-
fore installing timing belt cover.
Symbol Description
A TV damper bolt
T B EZT0007
AF
DOINE11AR11162
TIMING BELT LOWER COVER / UPPER COVER

INSTALLATION
R
1. Install timing belt lower cover (B) assy to en-

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

cylinder head front side and tighten the bolt
flange.
DOINE11AR11032 Standard value (T1) :
0.9 -1.1 kgm (9 -11 Nm, 6.51 -7.96 ft.lbs)
Symbol Description
A Timing belt upper cover
B Timing belt lower cover

11A ENGINE <CFE>
/ 42 CAMSHAFT AND CAMSHAFT OIL SEAL
CAMSHAFT AND CAMSHAFT OIL SEAL WCH11ASASSY12003
T
AF
R
D
DOINC11AR11008

ENGINE <CFE> 11A
CAMSHAFT AND CAMSHAFT OIL SEAL / 43
Sealant and Lubricant :

Part No. MD970389 or equivalent
Engine oil
Non-reusable
• Air Cleaner Removal and Installation (Refer to GROUP 015)
• Timing Belt Removal and Installation (Refer to 11A/32 )
• Exhaust Manifold Removal and Installation (Refer to GROUP 015).
• Water Hose and Water Pipe Removal and Installation (Refer to GROUP 014).
• Fuel discharged prevention (Refer to GROUP 13A – ON-VEHICLE SERVIS “Fuel Pressure).
• Spark plug Removal and Installation (Refer to GROUP 016).
Removal steps :
1. Bolt
2. Engine cover
3. Top plug coil
4. Cam position sensor connector
5. Breather hose
6. Cylinder head cover
7. VVT bolt cap
8. VVT sprocket
T
AF
9. Camshaft exhaust sprocket
10. Camshaft oil seal inlet
11. Camshaft oil seal exhaust
12. Bearing cap
13. Bearing cap
R
14. Camshaft inlet

15. Camshaft exhaust
16. Tappet
D
T1:0.5 - 0.7 kgm (5 - 7 Nm, 3.62 - 5.06 ft.lbs)

T2:1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
T3:0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T4:2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
T5:0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T6:3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 40° ± 2°
T7:6.0 kgm (60 Nm, 43.4 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs)
T8:3.0 - 3.4 kgm (30 - 34 Nm, 21.7 - 24.59 ft.lbs)

11A ENGINE <CFE>
LUBRICATION POINTS
T
AF
R
D
DOINC11AR11011

ENGINE <CFE> 11A
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
T
AF
R
D

11A ENGINE <CFE>
/ 46 CAMSHAFT AND TAPPET
CAMSHAFT AND TAPPET WCH11ASPROC12032

INSPECTION
TAPPET SELECTION PROCEDURE
CAUTION :
(1) The tappet clearance measurements should only be done after a minimum 2 hours of soaking.
(2) Ensure that cam sprocket timing marks in line with cam cover timing marks (crank is 90° ATDC).
(3) Cylinder head must be clamped with cylinder block to get achieve precise tappet clearance
measurement.
(4) Rotate cam sprocket clockwise direction as below sequence and measure the clearance using
thickness gauge.
Side Cam rotation Cam lobe number measurement

0° 1&2
90° 5&6
Inlet
180° 7&8
270° 3&4
T
0° 5&6
90° 7&8
Exhaust
180° 3&4
AF
270° 1&2
(5) Measure clearances X and Y (16 places) using a thickness gauge.
X = 0.2 ± 0.05
X = 0.3 ± 0.05
(6) If incorrect, select new tappets for correct clearance by using formula below.
Intake grade = Z + ( X – 0.2 )
R
Intake grade = Z + ( Y – 0.3 )
Symbol Description
X Tappet clearance for intake
D
Y Tappet clearance for exhaust

Z Tappet grade dimension
(7) Remove camshafts and known tappets, lubricate selected grade of tappets with oil and locate
in cylinder head assy.
(8) Install camshafts and caps without using sealant on front caps.
(9) Verify clearance X and Y (16 places) using a thickness gauge.
(10) Apply sealant as shown and install front caps.
(11) The sequence to secure camshaft front cap and camshaft intermediate cap as below :
Sequence 1st 2nd 3rd 4th 5th

Cam cap inlet I3 I4 I2 I5 I1
Cam cap exhaust E3 E4 E2 E5 E1

ENGINE <CFE> 11A
CAMSHAFT AND TAPPET / 47
T
AF
DOINE11AR11116
R
Symbol Description
A Intake camshaft
B Exhaust camshaft
D
C Tappets
D Cylinder head assy

11A ENGINE <CFE>
T
AF
DOINE11AR10012
R
1. STEP 1
1.1 Align markings (A) at VVT sprocket and exhaust camshaft sprocket to the cam cover top
marking 0°( 12 o’clock ) as shown in the illustration.
D
Symbol Description
A Camshaft sprockets marking
I Intake side
E Exhaust side
1.2 Measure tappet clearance using thickness gauge (View B) between tappet top surface and
camshaft lobe :
Camshaft lobe number for tappet clearance

Camshaft sprocket angle
Intake side Exhaust side
0°
No.1 and No.2 No.5 and No.6
(12 o’clock)

ENGINE <CFE> 11A
T
AF
DOINE11AR11163
R
2. STEP 2
2.1 Set markings (A) of VVT sprocket and exhaust camshaft sprocket at 90°( 3 o’clock ) as shown
in the illustration.
D
Symbol Description
I Intake side
E Exhaust side
camshaft lobe as below :

90°
(3 o’clock)

11A ENGINE <CFE>
T
AF
DOINE11AR11004
R
3. STEP 3
D
Symbol Description
I Intake side
E Exhaust side

180°
(6 o’clock)

ENGINE <CFE> 11A
T
AF
DOINE11AR11005
R
4. STEP 4
D
Symbol Description
I Intake side
E Exhaust side

270°
(9 o’clock)
5. Note all 16 pieces tappet clearance as shown in table below.
Tappet No. Tappet clearance measurement, X (intake)

1 X1
2 X2
3 X3
4 X4

11A ENGINE <CFE>

5 X5
6 X6
7 X7
8 X8
Tappet No. Tappet clearance measurement, Y (exhaust)
1 Y1
2 Y2
3 Y3
4 Y4
5 Y5
6 Y6
7 Y7
8 Y8
CAMSHAFT BEARING CAP REMOVAL
T 1. Loosen all bearing caps bolts based on the

loosening sequence as shown in the illustra-
tion.
AF
Symbol Description
I Intake side
E Exhaust side
R
DOINE11AR11064
TAPPET REMOVAL
D
1. Remove tappets using magnet tool (A).

CAUTION :
Do not mix the original tappet position.
DOIGE11AR03052

ENGINE <CFE> 11A
2. Refer tappet grade at all tappets as shown

in the illustration (inside the tappet).
3. Note all tappets grade in table below.
DOINE11AR11063
Tappet No. Tappet grade dimension Z (intake)

1 Z1
2 Z2
3 Z3
4 Z4
T
5 Z5
6 Z6
7 Z7
AF
8 Z8
Tappet No. Tappet grade dimension Z (exhaust)
1 Z1
2 Z2
3 Z3
R
4 Z4
5 Z5
6 Z6
D
7 Z7
8 Z8

TAPPET INSTALLATION
1. Refer table below for tappet clearance spe-
cification.
DOIGE11AR03122
Type Tappet clearance specification

Intake X = 0.2 mm ± 0.05 mm
Exhaust Y = 0.3 mm ± 0.05 mm

11A ENGINE <CFE>
Tappet clearance measurement Clearance specification Description

X1 0.23 mm Reuse old tappet
X1 < 0.17 mm Replace with new tappet
X1 > 0.23 mm Replace with new tappet
2. Refer formula below for intake and exhaust
tappet grade identification.
Intake Grade :
Z + ( X – 0.2 mm )
Exhaust Grade :
Z + ( Y – 0.3 mm )
Symbol Description ( in mm)

FOR EXAMPLE, THE CALCULATION BELOW
SHOWS THE INTAKE TAPPET GRADE SELECTION.
T Z + (X – 0.2mm) : 3.000 + (0.3 – 0.2)

: 3.000 + (0.1)
AF
: 3.100 mm
Due to 3.100 mm is very close to 3.105 mm, select
tappet grade 08
Mechanical tappet grade Dimension (A)

01 3.000
R
02 3.015
03 3.030
04 3.045
D
05 3.060
06 3.075
07 3.090
08 3.105
09 3.120
10 3.135
11 3.150
12 3.165
13 3.180
14 3.195
15 3.210
16 3.225
17 3.240
18 3.255
19 3.270
20 3.285
21 3.300

ENGINE <CFE> 11A

22 3.315
23 3.330
24 3.345
25 3.360
26 3.375
27 3.390
28 3.405
29 3.420
30 3.435
31 3.450
32 3.465
33 3.480
34 3.495
35 3.510
36 3.525
37
38
39
T 3.540
3.555
3.570
AF
40 3.585
41 3.600
42 3.615
43 3.630
44 3.645
R
45 3.660
46 3.675
47 3.690
D
3. Apply minimum sufficient amount of engine

oil on the tappet and insert all tappets inside
cylinder head assy.
DOINE11AR11066

11A ENGINE <CFE>
CAMSHAFT INSTALLATION
1. Apply engine oil to the camshafts.
2. Install the camshafts on the cylinder head.
Be careful not to confuse the VVT camshaft
with the exhaust camshaft.
Symbol Description
A VVT camshaft
Half moon shape at end portion
B
of VVT camshaft.
DOINE11AR11067
CAMSHAFT BEARING CAP INSTALLATION

1. Surface should be clean, dry and free from
grease and debris.
2. Apply sealant on front camshaft bearing cap
Specified sealant :
T TB1110B 2 mm (0.079 in) bead size.
Symbol Description
AF
A Front camshaft bearing cap
DOINE11AR11062
3. Before installing the other bearing caps, ar-

range the bearing caps by referring the
stamped identification marking on each the
R
bearing caps.
Identifica-
tion mark- Description
D
ing
A I (Intake side), E (exhaust side)
B Bearing caps number
C Arrow facing to timing belt
side
DOIGE11AR03056

ENGINE <CFE> 11A
4. Tighten bearing caps bolt using the following

tightening sequence order.

VVT cam-
I3 I4 I2 I5 I1
shaft cap
Exhaust
camshaft E3 E4 E2 E5 E1
cap
Steps Operation
Tighten camshaft caps in se-
quence using minimum force
S1
leaving an even gap between
cam caps and cylinder head.
Tighten camshaft cap evenly in
S2
sequence until the gap is closed
Tighten camshaft cap in se-
quence order to the specified
S3 torque :
T 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 -

7.96 ft.lbs)
AF
Symbol Description
DOINE11AR11060
B Leave even gap
C Bearing cap intermediate
I Intake side
E Exhaust side
R
NOTE :
Do not splash engine oil on the VVT camshaft
and exhaust camshaft cap cylinder head area.
D
5. Verify again all 16 pieces tappets clearance

Symbol Description
A Thickness gauge
B Camshaft lobe
6. If the tappets clearance is not within tappet
clearance specification , remove again all
camshaft bearing caps and select the correct
new tappet.
DOINE11AR10013

11A ENGINE <CFE>
VVT CAMSHAFT OIL SEAL INSTALLATION

oil to oil seal housing and oil seal lip.
2. Install special tool (inner) at the VVT cam-
shaft as shown in the illustration.
Symbol Description
A Special tool EZT 0006 (inner)
B VVT camshaft
C Oil seal housing
DOINE11AR11176
3. Securely insert new oil seal through the spe-

cial tool (inner).
Symbol Description
A Oil seal
B Special tool EZT 0006 (inner)
T
AF
DOINE11AR11177
4. Slowly and carefully knock the oil seal by

using special tool (outer).
5. Then, remove the special tool (inner) and
R
continue knocking the oil seal until it prop-

erly fitted at oil seal housing by using the
special tool (outer).
D
Symbol Description
A Oil seal
B Special tool EZT 0006 (outer)
C Mallet
DOINE11AR11178

ENGINE <CFE> 11A
EXHAUST CAMSHAFT OIL SEAL

INSTALLATION
2. Insert oil seal into the special tool (inner) and
then by using another part of the special tool
(outer), knock in the oil seal carefully using
mallet as shown in the illustration.
Symbol Description
A Oil seal housing
C Special tool EZT 0006 (outer)
D Mallet
E Oil seal
CAUTION :
Do not damage the oil seal during installa-
tion.
T
AF
DOINE11AR11179
OIL FILLER CAP INSTALLATION

R
Clean oil cap and cam cover sealing face from oil
trace/debris using soft cloth during oil change
or oil top-up.
D
DOINE11AR11065

11A ENGINE <CFE>
INSPECTION
CAMSHAFT
Measure the cam heights and replace the cam-
shaft if any height exceeds the specified limit.
Identification
Standard value
mark
Intake 45.05 mm (1.77 in)
Exhaust 44.70 mm (1.76 in)
Limit Value
Symbol Description
A Cam lobes heights measurement
B Micro meter
C Cam position lobes measurement
D Camshaft
T
AF
DOIGE11AR06170
R
D

ENGINE <CFE> 11A
CYLINDER HEAD GASKET / 61
CYLINDER HEAD GASKET WCH11ASASSY12016
T
AF
R
D
DOIQC11AR12001

11A ENGINE <CFE>
/ 62 CYLINDER HEAD GASKET
Engine oil
Non-reusable
• Fuel Discharge Prevention
• Engine Coolant Draining and Supplying (Refer Workshop Manual Chassis GROUP 014 – Cooling)
• Exhaust Manifold Removal and Installation (Refer Workshop Manual Chassis GROUP 015)
• Engine Oil Draining (Refer Workshop Manual Chassis GROUP 012)
Removal steps :
1. Bolt
2. Engine Cover
3. Engine wiring harness connector
4. Plug top coil
5. Cam cover
6. Cam cover seal
7. Sensor sub-harness connector
8. Thermostat pipe
9. Seal
10.
Clip return hose
11.
Thermostat return hose
12.
T
AF
13.
Oil cooler bracket
14.
Clamp hose
15.
Front radiator hose upper
16.
Cylinder head bolt
17.
Cylinder head
18.
Cylinder head gasket
R
19.
Cylinder block
T1: 0.5 - 0.7 kgm (5 - 7 Nm, 3.62 - 5.06 ft.lbs)
T2: 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T3: 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
D
T4: 3.3 - 3.5 kgm (33 - 35 Nm, 23.87 - 25.32 ft.lbs)

T5:
Steps Value Remarks
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm ● One bolt at a time
A
(2 Nm, 1.45 ft.lbs) ● Follow sequence No.1 to 10 for step
B 90° A , B and C
● Repeat each step until all bolts
C 90° achieve specification

ENGINE <CFE> 11A
POWER STEERING HOSE REMOVAL

Remove the power steering oil pump and
bracket assembly from the engine with the hose
attached as shown in illustration.
Symbol Description
A P / steering pressure hose
B Bracket p/ steering pressure hose
Air- cond compressor suction flexible
C
DOIQC11AR12007 hose
Bracket aircond compressor suction
D
flexible hose
E Engine mounting
NOTE :
Place the removed power steering oil pump in a
place where it will not be a hindrance when re-
T
moving and installing the cylinder head assembly,
and tie it with a cord.
THERMOSTAT PIPE ASSEMBLY REMOVAL

AF
1. Loosen the thermostat pipe assembly bolt
2. Release return hose clip from cylinder head
Symbol Description
A Thermostat pipe assembly bolt
R
B Hose Clip
D
DOINE11AR11013

11A ENGINE <CFE>
CYLINDER HEAD BOLT REMOVAL

Using the special tool, loosen the bolts in 2 or 3
steps in order of the numbers shown in the illus-
tration, and remove the cylinder head assembly.
CAUTION :
Because the plug guides cannot be replaced by
themselves, be careful not to damage or deform
the plug guides when removing the cylinder
head bolts.
Symbol Description
A Special tool (MB991653)
TBS Timing belt side
T
AF
DOIQC11AR12005

CYLINDER HEAD GASKET INSTALLATION
R
1. Wipe off all oil and grease from the gasket

mounting surface.
D
DOIGC11AR03045
2. Install so that the shapes of the cylinder head

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

ENGINE <CFE> 11A
CYLINDER HEAD BOLT INSTALLATION

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

3. Apply engine oil to the bolt threads and
washers.
DOIGE11AR03065
4. According to the tightening sequence as

shown in the illustration, tighten the bolts
Symbol Description
T
TIGHTENING PROCEDURES (SERVICE) :
Steps Value Remarks
3.0 kgm (30
AF
Nm, 21.7
A ft.lbs) ± 0.2
kgm (2 Nm,
1.45 ft.lbs)
B 90° (Min)
C 90° (Min)
R
D
DOIQC11AR12006
5. Give a 90° (refer table) turn to the cylinder

head bolts in the specified tightening se-
quence and give another 90° turn to the cyl-
inder head bolts.
Steps Value
C 90° (Min)
D 90° (Min)
Symbol Description
1 Special tool (MOT 591–04)
DOIGC11AR03152

11A ENGINE <CFE>
CAUTION :
1. If the bolt is turned less than 90°, 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 A.
THERMOSTAT PIPE ASSEMBLY

INSTALLATION
1. Apply a small amount of soap water to the
seal of the thermostat pipe assembly. Press
in to the water pump case assembly while
turning it left and right. Be careful not to
damage the seal. After installing, check that
the thermostat pipe assembly turn smoothly.
Symbol Description
A Thermostat pipe assembly
DOIHC11AR11003
T B Seal
2. If the seal does not turn smoothly, the seal
AF
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
R

B Seal in good fitting
C Front Seal
D
DOIGC11AR03051
D Impeller
E Water pump

ENGINE <CFE> 11A
CRANKSHAFT OIL SEAL / 67
CRANKSHAFT OIL SEAL WCH11ASASSY12006
T
AF
R
D
DOINC11AR11018

11A ENGINE <CFE>
/ 68 CRANKSHAFT OIL SEAL
Sealant :
— 3M Stud locking 4170 or equivalent
— Engine oil
• (A)- Dual Damper Flywheel Bolts
• (B)- Input transmission shaft hole.
• (C)- Lip section
Crankshaft front oil seal removal steps : Crankshaft rear oil seal removal steps :
• Timing belt (Refer to page 11A/32 ) • Transmission assembly CVT3.
• Crank angle sensor (Refer to 11A/72 ) (Refer to TRANSMISSION OVERHAUL– PUB. No
1. Crankshaft sprocket RDCE–11PNCH080 – 00)
2. Crankshaft front oil seal 3. Dual Damper Flywheel Bolts <CVT3>
4. Flywheel Assy <CVT3>
5. Crankshaft Bushing
6. Crankshaft rear oil seal.
T1 : 8.0 - 9.0 kgm (80 - 90 Nm, 57.86 - 65.1 ft.lbs)
T
AF
R
D

ENGINE <CFE> 11A
REMOVAL SERVICE POINT WCH11ASPROC12010
FLYWHEEL ASSY <CVT3> REMOVAL

1. Use the flywheel stopper to secure flywheel,
then remove the flywheel bolts as shown in
the illustration.
Symbol Description
A Dual damper flywheel (CVT3)
B Flywheel stopper (EZT0044)
C Flywheel assy <CVT3>
DOINE11AR11132

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

R
INSTALLATION
D
2. Tap the oil seal unit until it is flush with the

oil seal case.
Symbol Description
A Crankshaft
B Oil seal
DOIHC11AR04048
REAR OIL SEAL CASE INSTALLATION

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

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

entire periphery of the oil seal lip and install
the oil seal on the cylinder block.
FLYWHEEL PART MARKING
1. The part marking code describe the produc-
tion code and part number.
Symbol Description
1 Proton Part Number
( PWXXXXXXXX)
2 Production code
( XXXABC )
T
AF
R
DOINC11AR11019
D

ENGINE <CFE> 11A
FLYWHEEL ASSY <CVT3> INSTALLATION

1. Clean off sealant, oil and deposits from the
threaded portion of the flywheel assy and
dual damper flywheel bolts and input trans-
mission shaft hole.
2. Apply engine oil to the input transmission
shaft hole
3. Apply sealant to the threaded portion of the
dual damper flywheel bolt ( if the bolt is re-
used )
Specified sealant :
3M Nut Locking Part No. 4171 or equivalent
Symbol Description
1 Dual damper flywheel bolt
<CVT3>
2 Flywheel assy <CVT3>
3 Crankshaft bushing
T 4
T1
Crankshaft rear oil seal
8.0 - 9.0 kgm (80 - 90 Nm, 57.86
- 65.1 ft.lbs)
AF
DOINC11AR11020
4. Use the flywheel stopper (A), secure the fly-

wheel assy <CVT3> and tighten the bolts to
the specified torque.
R
Symbol Description
A Dual damper flywheel (CVT3)
D
B Special tool (EZT0044)

T1 8.0 - 9.0 kgm (80 - 90 Nm, 57.86
- 65.1 ft.lbs)
DOINE11AR11132

11A ENGINE <CFE>
/ 72 OIL PAN
OIL PAN WCH11ASASSY12005
T
AF
R
D
DOIRC11AR12001

ENGINE <CFE> 11A
OIL PAN / 73
Sealant :
PART No. MD970389 or equivalent
• Engine Oil Draining and Supplying
• Front Exhaust Pipe Removal and Installation (Refer to GROUP 015)
• A/C Compressor Removal and installation (Refer to GROUP 55 – On-Vehicle Service)
Removal steps :
Removal steps :
1. Oil drain plug

2. Washer
3. Oil level gauge guide
4. Catalytic converter bracket and exhaust bolt
5. Air-cond compressor bolt
6. Crank angle sensor
7. Oil filter
8. Oil pan
T
9. Baffle
10. Windage tray
11. Oil pickup pipe
AF
12. Oil ring
T5 : 1.2 - 1.6 kgm (12 - 16 Nm, 8.68 - 11.57 ft.lbs)
R
D

11A ENGINE <CFE>
/ 74 OIL PAN
OIL PAN REMOVAL

1. Remove 19 pieces oil pan bolts.
DOIME11AR11034
2. Remove the hidden oil pan bolt at the

transmission side (A).
Symbol Description
A Two bolts hidden at the loc-
ations shown.
B Oil pan
T
AF
R
D
DOIME11AR11033
3. Pry out the oil pan by using the flat screw

driver as shown in illustration.
CAUTION :
Slowly perform to avoid deformation of the
oil pan flange.
DOIME11AR11035

ENGINE <CFE> 11A
OIL PAN / 75

OIL PICKUP PIPE INSTALLATION
1. Slowly insert the oil pick up pipe oil seal (A)
to the oil pan hole. Carefully do not damage
the oil seal during installation. After installa-
tion, check condition the pipe fitting.
2. If the oil seal does not turn smoothly, the oil
seal is probably being clamped. Remove the
oil seal and check for any damage. If the oil
seal is damage, install a new oil seal by re-
DOIGE11AR03112
peating step no.1.
3. Tighten the oil pick up pipe bolts to the
specified torque.
Specified torque :
1.45 ft.lbs)
4. Tighten the baffle bolts in the sequence or-

der to the specified torque.
T Specified torque :
0.72 ft.lbs)
AF
Symbol Description
A Baffle
R
DOINE11AR11088
5. Tighten the windage tray bolts in the se-

D
quence order to the specified torque.

Specified torque :
0.72 ft.lbs)
Symbol Description
A Windage tray
DOINE11AR11089

11A ENGINE <CFE>
/ 76 OIL PAN
OIL PAN INSTALLATION

1. Clean the mating surfaces of the cylinder
block and oil pan from sealant. Wipe off the
pre-lubrication oil using isoprophyl alcohol.
2. Apply a 3 mm (0.12 in) ± 1 mm (0.039 in)
bead of form-in-place gasket to the outer
circumference of the oil pan flange.
Symbol Description
A Bolt hole
Specified sealant :
DOIGE11AR03070 Part No. MD970389 (Sealant – Threebond
TB1207F)
3. Tighten the bolts in the sequence order

Specified torque :
0.72 ft.lbs)
T
AF
DOINE11AR11087
OIL FILTER INSTALLATION

R
1. Clean the oil filter mounting surface on the

front case.
2. Apply a small amount of engine oil to the o-
D
ring at the new oil filter.
Symbol Description
A Oil filter o-ring
DOIGE11AR03111

ENGINE <CFE> 11A
OIL PAN / 77
3. Attach oil filter to housing thread and rotate

until oil filter seal is seated against seal face.
4. Use the special tool (MB991396) to tighten
the oil filter to the specified torque.
Specified torque : 1.2 - 1.6 kgm (12 - 16 Nm,
8.68 - 11.57 ft.lbs)
DOIGE11AR03071
T
AF
R
D

11A ENGINE <CFE>
/ 78 ENGINE ASSEMBLY
ENGINE ASSEMBLY WCH11ASASSY12007
T
AF
R
D
DOINC11AR11021

ENGINE <CFE> 11A
ENGINE ASSEMBLY / 79
Pre-removal Operation
• Disconnect battery terminal
• Disconnect Cannister hose
• Disconnec fuel real assy
• Transmission Removal (Refer to GROUP 23–CVT3)
• Fuel discharge Prevention (Refer to GROUP 13A)
• Draining Radiator Coolant (Refer to GROUP 14)
• Hood Removal (Refer to GROUP 42)
• Air Cleaner Removal (Refer to GROUP 15)
• Radiator Removal (Refer to GROUP14)
• Front Exhaust Pipe Removal (Refer to GROUP 15)
• Discharged Air condition system (Refer to GROUP 55)
Post-installation Operation
• Transmission Installation (Refer to GROUP 23–CVT3)
• Front Exhaust Pipe Installation (Refer to GROUP 15)
• Radiator Installation (Refer to GROUP14)
• Air Cleaner Installation (Refer to GROUP15)
• Hood Installation (Refer to GROUP 42)
• Fead Belt Tension Adjustment (Refer to 11A)
• Radiator coolant refilling
• Air condition system refilling
• Fuel charging
Removal steps
T
15. Oil control valve
AF
1. T– Mat sensor 16. Oil Preassure switch
2. Cam sensor 17. Alternator (S) connector
3. Crank sensor 18. Alternator (+) connector
4. Throttle body actuator 19. Starter (S) connector
5. Canister purge solenoid 20. Starter (+) connector
6. Ignition coil connector 1 21. Rear oxygen sensor
R
7. Engine wiring harness and Sub sensor wiring 22. Recirculation pump
harness
8. Map sensor 2
9. Front oxygen sensor
D
10. Ignition coil connector 1

14. Waste gate control

11A ENGINE <CFE>
T
AF
DOINC032R11001
R
Pre-removal operation
• Remove the under cover RH.
• Jack up the engine and transmission assembly until there is no weight on the engine mount
D
bracket insulator.
Removal steps
1. Power steering hose mounting bolt
A/C compression hose mounting bolt
3. Engine mounting bolt
4. Engine mounting nut
5. Engine mounting insulator mounting bolt
6. Engine mounting bracket
7. Engine mounting stopper
8. Radiator lower hose connection
9. Radiator upper hose connection
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 kgf.m
T2 : 5.0 ~ 6.4 kgf.m
T3* : 9.0 ~ 11.0 kgf.m

ENGINE <CFE> 11A
ON-VEHICLE SERVICE / 81
ON-VEHICLE SERVICE WCH11ASPROC12005
COMPRESSION PRESSURE CHECK

1. Before checking compression pressure, check
that the engine oil, starter and battery are
in normal condition. In addition, set the
vehicle to the pre-inspection condition.
2. Disconnect the top plug coil connector & re-
move top plug coil bolt.
Symbol Description
A Top plug coil bolt
B Top plug coil
T
DOINC11AR11002
3. Remove all of the spark plugs.

CAUTION
AF
Disconnect crank angle sensor connector in
order to prevent any ignition.
Symbol Description
C Spark plug socket
D Spark plug
R
D
DOINC11AR11003
4. Cover the spark plug hole with a shop towel

etc. After cranking the engine check there is
no foreign material adhere at the shop tow-
el.
Symbol Description
F Shop towel
CAUTION
(1) Keep away from the spark plug hole
when cranking because there may be
some material (e.g. water, oil, or fuel) in
the cylinder block, will become heated
DOINC11AR11004
and gush out from the spark plug hole.

11A ENGINE <CFE>
/ 82 ON-VEHICLE SERVICE
5. Set compression gauge to one of the spark

plug holes.
Symbol Description
D Compression gauge
E Shop towel
1 Depress the accelerator ped-
al (throttle valve fully
opened)
6. Crank the engine with the throttle valve fully
opened and measure the compression pres-
DOINC11AR11005
sure.
Standard pressure value at engine speed of
250-400 r/min :
Must be more than 160 psi
7. Measure the compression pressure for all the

cylinders.
Symbol Description
T D
1
Compression gauge
Depress the accelerator ped-
al (throttle valve fully
AF
opened)
Standard pressure value at engine speed of
250-400 r/min :
Each cylinder must be more than 160 psi
DOINC11AR11006
R
8. If there is a cylinder with compression less

than 160 psi, pour a small amount of engine
oil through the spark plug hole and repeat
D
the operations in steps (6) and (7).
Symbol Description
F Pour a small amount of en-
gine oil
• If the compression increased after engine
oil is added, the cause of the malfunction
is because of a worn or piston ring dam-
aged. (e.g. Cylinder inner surface scratch)
DOINC11AR11007 • If the compression does not rise after
engine oil is added, the cause is because
of a burnt of defective valve seat or
leaking at the gasket.
9. Reconnect the crank angle sensor connector.
10. Re-install the spark plugs and spark plug
cables.
11. Use the PADT to erase the diagnosis codes.
NOTE
This will erase the problem code related to
the disconnection of crank angle sensor.

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

GENERAL SPECIFICATIONS .......................................................... 11A/4
SPECIFICATIONS ..................................................................... 11A/4
SPECIAL TOOLS ........................................................................ 11A/4

TOOLS ................................................................................. 11A/4
PROTON ADVANCE DIAGNOSTIC TOOL PADT-II COMMUNICATION ........ 11A/6

SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/9
SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/13
SPECIAL FUNCTION ................................................................. 11A/14
VARIANT CODING- AIR CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/14
VARIANT CODING- AUTO CRUISE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/16
MODEL NAME READ AND WRITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/18
RESET VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/20
T
FEAD BELT DRIVE AND TV DAMPER PULLEY .................................... 11A/23
FEAD BELT DRIVE ...................................................................... 11A/25

AF
TV DAMPER PULLEY .................................................................. 11A/27

R
ALTERNATOR ........................................................................... 11A/29

D
TIMING BELT ........................................................................... 11A/31

INSTALLATION SERVICE POINTS ................................................. 11A/34
TIMING BELT / TIMING BELT TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/34
CAMSHAFT AND CAMSHAFT OIL SEAL ........................................... 11A/41

LUBRICATION POINTS .............................................................. 11A/43
CYLINDER HEAD GASKET ........................................................... 11A/49

CRANKSHAFT OIL SEAL .............................................................. 11A/55


11A ENGINE <IAFM+>
/2 Content
OIL PAN ................................................................................. 11A/61

ENGINE ASSEMBLY ................................................................... 11A/66


COMPRESSION PRESSURE CHECK ................................................ 11A/70
T
AF
R
D

ENGINE <IAFM+> 11A
Content /3
NOTE
T
AF
R
D

11A ENGINE <IAFM+>
GENERAL SPECIFICATIONS WCH11ASPECS12002
SPECIFICATIONS
Specifications
Items
Campro IAFM+
Total displacement 1597 cm³ (97.45 cu.in)
Bore x stroke 76.0 x 88.0 mm (2.99 x 3.46 in)
Direction of Rotation Clockwise (From front : SAE)
Number of cylinders 4
Valve train DOHC 16V
Combustion chamber Pentroof type
Firing order 1–3–4–2
Compression ratio 10:1
Tappet Hydraulic latch adjuster
Intake 8
Number of valve
Exhaust 8
Intake open BTDC 12°
Valve timing
Intake close
Exhaust open
T ABDC 48°
BBDC 45°
AF
Exhaust close ATDC 10°
Battery 55D23L
Electrical System Alternator 12V – 90A
Starter max-output 12V – 1.2kW
Type Electronic controlled multipoint fuel injection
Fuel system
R
Fuel Ron 97
Lubrication system Pressure feed, full-flow filtration
Engine oil capacity 3.75 Litre
D
Oil pump type Trochoid type

Fuel system Electronic controlled multipoint fuel injection
Water pump type Centrifugal impeller type
Cooling system Water-cooled forced circulation
TOOLS
EZT0047 PADT-II VCI Kits For vehicle diagnosis, ECU,
Flashing, vehicle measurement
and troubleshooting
DOIMC35BR11039

ENGINE <IAFM+> 11A
SPECIAL TOOLS /5

EZT 0044 Flywheel Stopper To lock flywheel .
DOIME11AR11051
MD990767 End yoke holder Holding the camshaft sprocket
DOIIC11AR9003
MD998719 or Crankshaft pulley Holding the camshaft sprocket

MD998754 holder pin
T
AF
DOIIC11AR9004
MD998718 Crankshaft rear oil seal Press in of the crankshaft rear

installer oil seal
R
DOIIC11AR9008
A: MD998304 A: Crankshaft front oil Press-in of the crankshaft

B: MD998305 seal installer front oil seal
D
B: Crankshaft front oil

seal guide
DOIIC11AR9009
MB991653 Cylinder head bolt Cylinder head bolt removal

wrench and installation
DOIIC11AR9010

DOIIE11AR9004

11A ENGINE <IAFM+>

MOT 591–04 Angle gauge To get accurate angle during
and TV damper bolt
DOIGC11AR03151
EZT 0003 TV damper stopper To lock TV damper from turn-

ing
DOIGE11AR03105
EZT 0004 Camshaft sprocket To prevent camshaft sprocket

stopper from turning during installing
timing belt
DOIGE11AR03134
T
AF
staller seal
R
DOIGE11AR03155

D
DOIGE11AR03146
PROTON ADVANCE DIAGNOSTIC TOOL PADT-II COMMUNICATION

WCH11ASPROC12027
SPECIAL FUNCTION DESCRIPTION


- Air condition

ENGINE <IAFM+> 11A

- Clear key
gine ECU
PADT-II PREPARATION
1. Connect PADT-II to diagnostic connector
Symbol Description
T B
C
OBD-II cable
USB cable
AF
DOIMC35BR11048
R
D
DOINC11AR11026

11A ENGINE <IAFM+>

PADT-II menu.
Symbol Description
T
AF
R
D
DOINC11AR11027


ENGINE <IAFM+> 11A
T
AF
DOINC11AR11028
R

available system.
Symbol Description
D
B ID icon
SECURITY
DOIMC11AR11071
SPECIAL FUNCTION DESCRIPTION WCH11ASPROC12028

11A ENGINE <IAFM+>

- Air condition
- Clear key
gine ECU
PADT-II PREPARATION
T 1. Connect PADT-II to diagnostic connector

AF
Symbol Description
B OBD-II cable
C USB cable
R

DOIMC35BR11048
D

ENGINE <IAFM+> 11A
T
AF
DOINC11AR11026
R

PADT-II menu.
Symbol Description
D

11A ENGINE <IAFM+>
T
AF
DOINC11AR11027
R

D

ENGINE <IAFM+> 11A
T
AF
DOINC11AR11028
R

available system.
Symbol Description
D
B ID icon
SECURITY
DOIMC11AR11071

11A ENGINE <IAFM+>
SPECIAL FUNCTION WCH11ASPROC12029
VARIANT CODING- AIR CONDITION
T
AF
R
DOINC11AR11030

D

diagnosis activity.
Symbol Description
Functions’
C Coding selection ‘Air Condition’

ENGINE <IAFM+> 11A

procedure.
DOIMC11AR11037

down menu to change the status.
T
AF
DOIMC11AR11038

R
D
DOIMC11AR11039

11A ENGINE <IAFM+>
VARIANT CODING- AUTO CRUISE SETTING
T
AF
R
DOINC11AR11031

D
diagnosis activity.
Symbol Description
Functions’
C Coding selection ‘Auto Cruise
Setting’

ENGINE <IAFM+> 11A

procedure.
DOIMC11AR11041

down menu to change status.
T
AF
DOIMC11AR11042

R
D
DOIMC11AR11043

11A ENGINE <IAFM+>
MODEL NAME READ AND WRITE WCH11ASPROC12030
T
AF
R
DOINC11AR11034

)
D
Symbol Description
Functions’
C Function selection ‘Model Name
Read and Write’

ENGINE <IAFM+> 11A

procedure.
DOIMC11AR11058
3. Key in the new model name in the text box

using capital letters.
T
AF
DOIMC11AR11060

ignition at ON position.
R
D
DOIMC11AR11061
5. Check that the model name is correct.

Press exit to return to main menu.
DOIMC11AR11062

11A ENGINE <IAFM+>
RESET VALUES
T
AF
R
DOINC11AR11035

)
D
Symbol Description
Functions’
C Function selection ‘Reset Func-
tion’

ENGINE <IAFM+> 11A

procedure.
DOIMC11AR11064
3. Select ‘Reset Oxygen Control Adaptation’.

T
AF
DOINC11AR11037
4. The reset oxygen control adaptation is suc-

cessful.
Then select ‘Reset Throttle Adaptation’ and
R

D
DOINC11AR11038
5. The reset throttle adaptation is successful.

Then select ‘Reset Torque Loss Adaptation
and press next to continue.
DOINC11AR11036

11A ENGINE <IAFM+>
6. Please wait while the system is being reset.

Reconfirm that value status must be ‘0%’.
DOIMC11AR11068
7. The process is finished.

T
AF
DOIMC11AR11070
R
D

ENGINE <IAFM+> 11A
FEAD BELT DRIVE AND TV DAMPER PULLEY / 23
FEAD BELT DRIVE AND TV DAMPER PULLEY WCH11ASASSY12008
T
AF
R
DOIMC11AR07003
D

• Under Cover Removal and Installation (Refer to GROUP 051 — Lower Cover)
Removal steps :
1. Tensioner bolt
2. Tensioner bolt
3. Tensioner
4. FEAD belt
5. TV damper bolt
6. TV damper pulley
T1 : 4.8-5.2 kgm (48-52 Nm, 34.72-37.61 ft.lbs)
T2 : 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
T3 : 3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 120°± 4°

11A ENGINE <IAFM+>
/ 24 FEAD BELT DRIVE AND TV DAMPER PULLEY
T
AF
DOIGC11AR03021
R
Fead belt route

1. Tensioner Accessory Drive pulley
2. TV damper pulley
D
3. Air-cond Compressor pulley

4. Power steering pump pulley
5. Water pump pulley — upper side
6. Alternator pulley
7. Water pump pulley — lower side

ENGINE <IAFM+> 11A
FEAD BELT DRIVE / 25
FEAD BELT DRIVE WCH11ASPROC12020

FEAD BELT REMOVAL
arm.
Symbol Description
A Ratchet
DOIGC11AR03025

or.
T Symbol
A Ratchet
Description
AF
DOIGC11AR03026

R

D

torque.
Symbol Description
4.8-5.2 kgm (48-52 Nm, 34.72-
DOIGC11AR03027 T1
37.61 ft.lbs)
2.2-2.6 kgm (22-26 Nm, 15.91-
T2
18.81 ft.lbs)

11A ENGINE <IAFM+>
/ 26 FEAD BELT DRIVE

roller nicely.
NOTE
Symbol Description
1 Fead belt
DOIGC11AR03028

arm.
Symbol Description
A Ratchet
T
AF
DOIGC11AR03029

R
Symbol Description
A Ratchet
1 TV damper
D
2 Compressor pulley
4 Water pump pulley
DOIGC11AR03030

Symbol Description
A Ratchet
5 Alternator pulley
6 Water pump pulley
DOIGC11AR03031

ENGINE <IAFM+> 11A
TV DAMPER PULLEY / 27
TV DAMPER PULLEY WCH11ASPROC12018

TV DAMPER BOLT REMOVAL
1. Use the special tool TV damper stopper to
hold the TV damper and then loosen the TV
damper bolts.
Symbol Description
A TV damper stopper
B TV damper bolt
C TV damper pulley
D Dowel
E Crankshaft
T
AF
DOIGC11AR03089

TV DAMPER BOLT INSTALLATION
R
1. Install the TV damper, use the special tool

TV damper stopper to hold the TV damper
and then tighten the TV damper bolt.
D
Symbol Description
A TV damper stopper
B TV damper bolt
C TV damper pulley
D Dowel
E Crankshaft
DOIGC11AR03089

11A ENGINE <IAFM+>
/ 28 TV DAMPER PULLEY
2. Used the special tool angle gauge to torque

the tv damper bolt at the torque value as
specified.
1.45 ft.lbs) + 120° ± 4°
Symbol Description
G TV damper pulley
H Angle gauge MOT
591–04
DOIGC11AR03166 I TV damper stopper
J Ratchet
T
AF
R
D

ENGINE <IAFM+> 11A
ALTERNATOR / 29
ALTERNATOR WCH11ASASSY12014
T
AF
R
DOIQC11AR11005
D

• Fead Belt Removal And Installation (Refer to 11A/23 )
• Splash Shield Rh Removal And Installation (Refer to GROUP 042 – Body)
Removal steps :
1. Tensioner assy drive pulley
2. Fead belt
3. Alternator
T3: 4.8-5.2 kgm (48-52 Nm, 34.72-37.61 ft.lbs)
T4: 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)

11A ENGINE <IAFM+>
/ 30 ALTERNATOR

1. Install alternator with special bolt together
with nut to front cover assy. Pre-tighten the
bolts 2 ~ 3 times and lift up alternator to the
correct position.
2. Tighten the upper bolt to the specified
torque.
2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.2 kgm (2
DOINC11AR11009
Nm, 1.45 ft.lbs)
Symbol Description
A Upper bolt
B Special bolt
3. Tighten alternator nut to the specified
torque.
T 3.5 kgm (35 Nm, 25.32 ft.lbs) ± 0.2 kgm (2

Nm, 1.45 ft.lbs)
AF
Symbol Description
C Nut
R
DOINC11AR11010
D

ENGINE <IAFM+> 11A
TIMING BELT / 31
TIMING BELT WCH11ASASSY12011
T
AF
R
DOIQC11AR12009
D

• Disconnect Battery
• Lower Cover Removal and Installation (Refer to GROUP 051)
• Engine Mounting Removal and Installation (Refer to GROUP 032).
• Fead Belt Drive / TV Damper Removal and Installation (Refer to 11A/23 ).
• Support engine with crocodile jack.
Removal steps :
1. Belt cover lower
2. TV damper pulley
4. Belt cover top
5. Engine Mounting Bracket
6. Timing belt tensioner
7. Timing belt
8. Crankshaft sprocket

11A ENGINE <IAFM+>
/ 32 TIMING BELT
T2 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T4 : 2.4 - 2.6 kgm (24 - 26 Nm, 17.36 - 18.81 ft.lbs)
T5 : 3.3 - 3.7 kgm (33 - 37 Nm, 23.87 - 26.76 ft.lbs)
T6 : 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)
T
AF
R
D

ENGINE <IAFM+> 11A
TIMING BELT / 33

REMOVAL
1. Align camshaft sprocket timing marks ‘‘A’’
to features on cam cover ‘‘B’’ with the aid of
the cam sprocket alignment tool.
Symbol Description
A Camshaft sprocket timing marks
B Cam cover
C Align dowel
D Front case
T
AF
DOIMC11AR11008
2. Align crankshaft to 90° ATDC (align dowel

’C’’ to one o’clock feature on front case’’D’’),
by using the special tool together with TV
R
damper bolt, turn the crankshaft sprocket

until get the actual align.
Symbol Description
D
C Align dowel
D Front case mark
E TV damper bolt
F Special tool - EZT 0007
DOIMC11AR11004

11A ENGINE <IAFM+>
/ 34 TIMING BELT
3. ‘‘STOP’’ the camshaft sprocket from turning

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

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

ceed to remove the timing belt.
CAUTION
R
In order to remove the tensioner bolt, make

sure to use the correct single type socket box
because it can prevent the head bolt from
D
damage and wear
Symbol Description
B Ratchet
DOINE11AR11021 C Tensioner

WCH11ASPROC12014

INSTALLATION
1. Align camshaft sprocket timing marks (B)
with cam cover marks (A) and lock using
special tool EZT 0004 (C) as shown in illustra-
tion.
NOTE :
DOIME11AR11017

ENGINE <IAFM+> 11A
TIMING BELT / 35
Symbol Description
A Sprocket marks
B Cam cover marks
C Special tool (EZT 0004)
2. By using the special tool (EZT 0007) align the
crankshaft sprocket to 90° ATDC (dowel pin)
“C” is aligned to “D” at one o'clock feature
on front case).
Symbol Description
pin
E TV damper bolt
DOIGE11AR03024
3. Fit tensioner bearing (A) by putting the foot

into the core plug (B) indent and ensuring
T the allen key socket is positioned opposite

the foot as shown in illustration.
4. Then tighten tensioner bolt (C) by hand.
AF
Symbol Description
A Tensioner bearing
B core plug
C Tensioner bolt
R
DOINE11AR11058

D

DOIGE11AR03177

11A ENGINE <IAFM+>
/ 36 TIMING BELT

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

indicator is exactly over the right hand side
edge of indicator notch (refer view B).
R
Tighten tensioner bolt whilst holding the al-

len key in place.
Specified torque :
D
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2

Nm, 1.45 ft.lbs)
DOIME11AR11019

ENGINE <IAFM+> 11A
TIMING BELT / 37

damper bolt (E), rotate the engine twice
(720º crankshaft rotation). Ensure crankshaft
dowel pin (C) back aligned with front case
marks (D).
CAUTION :
position before rotate.
DOIGE11AR03024

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

11A ENGINE <IAFM+>
/ 38 TIMING BELT
10. If the indicator does not stop within the

while loosening tensioner bolt with torque
on (view D).
T
AF
DOIME11AR11021
11. Rotate tensioner bearing clockwise until the

pointer is positioned in the centre of the
R
12. Retighten tensioner bolt whilst holding the

allen key in place.
Specified torque :
D
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2

Nm, 1.45 ft.lbs)
DOIME11AR11022

ENGINE <IAFM+> 11A
TIMING BELT / 39
13. Rotate the crankshaft 720º until it reach to

safe point (90º ATDC)
14. CAUTION :
position.
NOTE :
(1) Camshaft sprocket timing marks (A) are
aligned by cam cover timing marks (B).
(2) Crankshaft sprocket dowel pin (C) is
aligned with front case marks (D).
Symbol Description
A Camshaft sprocket timing
marks
B Cam cover marks
pin
D Front case mark
T
AF
DOIME11AR11023

sition in the centre of the notch scale, the
belt is properly tensioned and the task is
R
complete. If the indicator does not stop in

the middle of the notch scale, then repeat
steps (10 until 14).
D
DOIME11AR11020

11A ENGINE <IAFM+>
/ 40 TIMING BELT

again the special tool EZT 0004 (G) in
between of two camshaft sprockets in order
to make sure the camshaft sprocket “STOP”
from turning.
Symbol Description
G EZT0004
DOIME11AR11013
17. Then, turn TV damper bolt (A) anti-clockwise

to loose TV damper bolt and special tool (B).
Symbol Description
A TV damper bolt
T B EZT 0007
AF
DOINE11AR11162
TIMING BELT LOWER COVER / UPPER COVER

INSTALLATION
R

bolt flange.
Standard value (T1) :
D
0.9 -1.1 kgm (9 -11 Nm, 6.51 -7.96 ft.lbs)

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

ENGINE <IAFM+> 11A
CAMSHAFT AND CAMSHAFT OIL SEAL WCH11ASASSY12010
T
AF
R
D
DOIQC11AR12004

11A ENGINE <IAFM+>
Sealant and Lubricant :

Part No. MD970389 or equivalent
Engine oil
Non-reusable
• Air Cleaner Removal and Installation (Refer to GROUP 015 — Air cleaner).
• Exhaust Manifold Removal and Installation (Refer to GROUP 015 — Exhaust Manifold).
• Water Hose and Water Pipe Removal and Installation (Refer to GROUP 014).
• Fuel discharged prevention (Refer to GROUP 13A — ON-VEHICLE SERVICE “Fuel Pressure Check”).
• Spark Plug Removal and Installation (Refer to GROUP 016).
Removal steps :
1. Bolt
2. Engine Cover
3. Top plug coil
4. Cam position sensor connector
5. Breather hose
6. Cylinder head cover
7. Camshaft sprocket
T
AF
8. Camshaft sprocket
9. Camshaft oil seal inlet
10. Camshaft oil seal exhaust
11. Bearing cap
12. Bearing cap
R
13. Camshaft inlet

14. Camshaft exhaust
15. Tappet
D
T1 : 0.5 - 0.7 kgm (5 - 7 Nm, 3.62 - 5.06 ft.lbs)

T3 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T4 : 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
T5 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)

ENGINE <IAFM+> 11A
LUBRICATION POINTS
T
AF
R
D
DOIMC11AR07006

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

ENGINE <IAFM+> 11A
CAMSHAFT SPROCKET REMOVAL

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

Loosen the bolt bearing cap in order as shown
in the illustration, and remove the bearing cap
in sequence as the number mark indicated.
Symbol Description
T E
I Intake
Exhaust
AF
DOIGC11AR03150
TAPPET REMOVAL
Use magnetic tool to remove the tappet.
R
Symbol Description
A Magnet tool
D
DOIGE11AR03052
TAPPET INSPECTION
Check tappet by pressing the lash adjuster in the
tappet, if the lash adjuster is hard to press it
mean ‘‘a good condition’’. If the lash adjuster is
easily to press, it means the tappet is in ‘‘No
good condition’’. Replace with a new tappet.
Symbol Description
A Lash adjuster
Hard to press Good condition
Easy to press No good condition
DOIGE11AR03147

11A ENGINE <IAFM+>

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

1. Set the camshaft dowel pins in the positions
T Symbol Description
Intake camshaft dowel pin
angle;
AF
A
10°- 15° or 11 o'clock posi-
tion
Exhaust camshaft dowel
pin angle;
B
DOIGE11AR06180 10°- 15° or 11 o'clock posi-
tion
R
NOTE :
Place the notch for tightening the camshaft
head bolt in the correct position.
D
2. The bearing cap intermediate are the same

shape. Before they are installed, check the
cap number (B) and the intake and exhaust
identification marks (A).
Identification mark : (stamped on front and
intermediate bearing caps)
Mark (A) Description

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

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

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

torque sequence.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Tightening sequence
1 3 5 7 9
T
Intake [I]
2 4 6 8 10
Exhaust 1 3 5 7 9
AF
[E] 2 4 6 8 10
DOIGC11AR03040
NOTE :
Don’t splash engine oil on the 1st. inlet and
exhaust camshaft cap cylinder head area.
CAMSHAFT OIL SEAL INSTALLATION

R

oil to oil seal housing and oil seal (A) lip.
2. Insert oil seal into the camshaft oil seal in-
D
staller (EZT 0006) by using the special tool.

Knock-in the oil seal carefully and slowly as
Symbol Description
A Oil seal
Camshaft oil seal installer (EZT
B
DOIGC11AR03167 0006)
NOTE :
Do not damage the oil seal, which will cause
malfunction of the oil seal.

11A ENGINE <IAFM+>
CAMSHAFT SPROCKET INSTALLATION

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

sprocket from moving.
3. Tighten the camshaft sprocket bolt to the
R
specified torque.
Specified torque :
D
1.45 ft.lbs) + 40° ± 2°
DOIGC11AR03034
CAM POSITION SENSOR INSTALLATION

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

ENGINE <IAFM+> 11A
CYLINDER HEAD GASKET WCH11ASASSY12009
T
AF
R
D
DOIQC11AR12003

11A ENGINE <IAFM+>
Engine oil
Non-reusable
• Fuel Discharge Prevention
• Engine Coolant Draining and Supplying (Refer Workshop Manual Chassis GROUP 014 – Cooling)
• Exhaust Manifold Removal and Installation (Refer Workshop Manual Chassis GROUP 015)
• Engine Oil Draining (Refer Workshop Manual Chassis GROUP 012)
Removal steps :
1. Bolt
2. Engine Cover
3. Engine wiring harness connector
4. Plug top coil
5. Cam cover
6. Cam cover seal
7. Sensor sub-harness connector
8. Thermostat pipe
9.Seal
10.
Clip return hose
11.
12.
T
AF
13.
Intake manifold stay bracket
14.
Clamp hose
15.
Front radiator hose upper
16.
Cylinder head bolt
17.
Cylinder head
18.
Cylinder head gasket
R
19.
Cylinder block
T1: 0.5 - 0.7 kgm (5 - 7 Nm, 3.62 - 5.06 ft.lbs)
T3: 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
D
T4: 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)

T5:
Steps Value Remarks
A 2.0 kgm (20 Nm, 14.47 ft.lbs) ● One bolt at a time
B 4.0 kgm (40 Nm, 28.93 ft.lbs) ● Follow sequence No. 1 to 10 for step
A , B and C
5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.2 kgm
C ● Repeat each step until all bolts achieve
(2 Nm, 1.45 ft.lbs)
specification
D 60°
E 60°

ENGINE <IAFM+> 11A
POWER STEERING HOSE REMOVAL

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

1. Loosen the thermostat pipe assembly bolt
2. Release return hose clip from cylinder head
Symbol Description
A Thermostat pipe assembly bolt
T B Hose Clip
AF
DOINE11AR11013

Using the special tool, loosen the bolts in 2 or 3
steps in order of the numbers shown in the illus-
R
tration, and remove the cylinder head assembly.

CAUTION :
Because the plug guides cannot be replaced by
D
themselves, be careful not to damage or deform

the plug guides when removing the cylinder
head bolts.
Symbol Description
DOIGC11AR03044

11A ENGINE <IAFM+>

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

holes match the shapes of the respective
cylinder head gasket holes.
Symbol Description
A Cylinder head
B Bushing
T
AF
DOIMC11AR11002

R

place the bolt.
Limit:
D
Max. 160 mm (6.3 in) ± 0.35 mm (0.014 in)

washers.
DOIGE11AR03065

ENGINE <IAFM+> 11A

Symbol Description
T
AF
DOIGC11AR03048

Steps Value Remarks
R
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.2

A
kgm (2 Nm, 1.45 ft.lbs)
4.0 kgm (40 Nm, 28.93 ft.lbs) ± 0.2
B
D
kgm (2 Nm, 1.45 ft.lbs) (1) One bolt at time.

5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.2 (2) Follow sequence No. 1 to 10 for steps
C A, B, & C.
(3) Repeat each step until all bolts achieve
60° + 4° (Max)
D specification.
60° (Min)
60° + 4° (Max)
E
60° (Min)

11A ENGINE <IAFM+>
5. Give a 60° + 4° (refer table) turn to the cylin-

der head bolts in the specified tightening
sequence and give another 60° turn to the
cylinder head bolts.
Value
60° + 4° (Max)
60° (Min)
Symbol Description
1 Special tool (MOT 591–04)
CAUTION :
DOIGC11AR03152
1. If the bolt is turned less than 60°, proper
fastening performance may not be expected.
When tightening the bolt, therefore, be careful
to give a sufficient turn to it.
2. If the bolt is overtightened, loosen the bolt
completely and then retighten it by repeating
the tightening procedure from step 1.
T Value
60° + 4° (Max)
60° (Min)
AF
THERMOSTAT PIPE ASSEMBLY
INSTALLATION
seal of the thermostat pipe assembly. Press
in to the water pump case assembly while
R
turning it left and right. Be careful not to

damage the seal. After installing, check that
the thermostat pipe assembly turns smoothly.
D
Symbol Description
DOIHC11AR11003 B Seal
is probably being clamped. Disconnected the
for damage. After this, re- insert the new
procedure no. 1.
Symbol Description
C Front Seal
DOIGC11AR03051
D Impeller
E Water pump

ENGINE <IAFM+> 11A
CRANKSHAFT OIL SEAL WCH11ASASSY12012
T
AF
R
D
DOIMC11AR11018

11A ENGINE <IAFM+>
Sealant :
— 3M Stud locking 4170 or equivalent
— Engine oil
• (A)- Crankshaft
• (B)- Engine oil bolt washer surface
• (C)- Lip section
Crankshaft front oil seal removal steps : Crankshaft rear oil seal removal steps :
• Timing belt (Refer to page 11A/31 ) • Transmission assembly
• Crank angle sensor (Refer to 11A/61 ) (M/T: Refer to the basic publication, GROUP
1. Crankshaft sprocket 22)
2. Crankshaft front oil seal • Transmission assembly
(A/T: Refer to the basic publication, GROUP
23)
• Clutch cover and disc <M/T>
3. Damper Bolts<CVT2>
4. Damper Assy
5. Flywheel Bolt>
T
6. Flywheel Assy <5TT200A>
7. Flywheel Assy <CVT2>
8. Crankshaft Bushing.
AF
9. Crankshaft rear oil seal.
T1 : 1.7 - 1.9 kgm (17 - 19 Nm, 12.3 - 13.74 ft.lbs)
T2 :12.0 - 13.0 kgm (120 - 130 Nm, 86.8 - 94.03 ft.lbs)
R
D

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

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

Refer to Chassis Workshop Manual Group 21C –
CLUTCH – Removal and Installation (RDCE –
08MA010 – 05)
T
FLYWHEEL ASSY <CVT2> REMOVAL
AF
the illustration.
Symbol Description
A Flywheel bolts
B Flywheel stopper (EZT0044)
R
DOIME11AR11044
D
FLYWHEEL ASSY <5MTT200A> REMOVAL

the illustration.
Symbol Description
A Flywheel stopper (EZT0044)
B Flywheel assy <5MTT200A>
C Flywheel bolts
DOIME11AR11045

11A ENGINE <IAFM+>

CRANKSHAFT REAR OIL SEAL INSTALLATION
the illustration.
Symbol Description
A Special tool EZT 0011
B Oil seal
D Mallet hammer
DRIVE PLATE <A/T> / FLYWHEEL <M/T> /

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

INSTALLATION
R

2. Tap the oil seal unit until it is flush with the
D
oil seal case.
Symbol Description
A Crankshaft
B Oil seal
DOIIC11AR9032

at the illustrated position if it has no pre-
formed gasket attached.
Specified sealant :
CAUTION :

ENGINE <IAFM+> 11A

FLYWHEEL ASSY <5MTT200A> / FLYWHEEL

ASSY <CVT2> INSTALLATION
threaded portion of the drive plate/adapter
plate tightening bolts and from the threaded
holes on the crankshaft.
2. Apply engine oil to the bolt flange and to
the threaded holes on the crankshaft.
3. Apply sealant to the treaded portion of the
bolt ( if the bolt is reused )
Specified sealant :
4. Install flywheel or drive plate to the crank-

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

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

wheel assy <CVT2> or flywheel assy
<5MTT200A> and tighten the bolts to the
specified torque.
Symbol Description
A Flywheel stopper (EZT0044)
B Flywheel assy <5MTT200A>
C Flywheel bolts
D Flywheel assy <CVT2>
T2 12.0 - 13.0 kgm (120 - 130 Nm,
86.8 - 94.03 ft.lbs)
T
AF
DOIQC11AR12010
DAMPER ASSY <CVT2> INSTALLATION

1. Use the flywheel stopper (C) to secure fly-
R
wheel, then tighten the damper assy <CVT2>

bolts (D) as shown in the illustration.
Symbol Description
D
A Flywheel assy <CVT2>

B Damper assy <CVT2>
C Flywheel stopper (EZT0044)
D Damper assy <CVT2> bolts
DOIME11AR11043
CLUTCH PLATE M/T <5MTT200A>
INSTALLATION
Refer to Group 21C – CLUTCH – Removal and In-
stallation

ENGINE <IAFM+> 11A
OIL PAN / 61
OIL PAN WCH11ASASSY12017
T
AF
R
D
DOIQC11AR12008

11A ENGINE <IAFM+>
/ 62 OIL PAN
Sealant :
PART No. MD970389 or equivalent
• Engine oil draining and supplying
• Front exhaust pipe removal and installation (Refer to GROUP 015)
• A/C compressor removal and installation (Refer to GROUP 055 – On-Vehicle Service)
Removal steps :
Removal steps :
1. Oil drain plug

2. Washer
4. Catalytic converter bracket and exhaust bolt
5. Air cond compressor bolt
7. Oil filter
8.Oil pan
9.Baffle
10.
Oil pickup pipe
11.
Oil ring
T
AF
T3 : 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T5 : 1.2 - 1.6 kgm (12 - 16 Nm, 8.68 - 11.57 ft.lbs)
R
D

ENGINE <IAFM+> 11A
OIL PAN / 63
OIL PAN REMOVAL

DOIME11AR11034

Symbol Description
ations shown.
B Oil pan
T
AF
R
D
DOIME11AR11033

CAUTION :
oil pan flange.
DOIME11AR11035

11A ENGINE <IAFM+>
/ 64 OIL PAN

1. Slowly insert the oil pick up pipe oil seal (A)
to the oil pan hole. Carefully do not damage
DOIGE11AR03112
peating step no.1
specified torque.
Specified torque :
1.45 ft.lbs)

T Specified torque :
0.72 ft.lbs)
AF
Symbol Description
A Baffle
R
DOINE11AR11088

D

2. Apply a 3 mm (0.12 in) ± 1 mm (0.039 in)
Symbol Description
A Bolt hole
Specified sealant :
TB1207F).

ENGINE <IAFM+> 11A
OIL PAN / 65

Specified torque :
0.72 ft.lbs)
DOINE11AR11087

front case.
T Symbol
A
Description
Oil filter o-ring
AF
DOIGE11AR03111

R

8.68 - 11.57 ft.lbs)
D
DOIGE11AR03071

11A ENGINE <IAFM+>
ENGINE ASSEMBLY WCH11ASASSY12013
T
AF
R
D
DOIMC11AR07034

ENGINE <IAFM+> 11A
• Transmission Removal (Refer to page 22/19 for MT and page 23/66 for CVT)
• Fuel discharge Prevention (Refer to the basic publication, GROUP 13A)
• Draining Radiator Coolant (Refer to the basic publication, GROUP 14)
• Hood Removal (Refer to the basic publication, GROUP 42)
• Air Cleaner Removal (Refer to page GROUP 15)
• Radiator Removal (Refer to page GROUP 14)
• Front Exhaust Pipe Removal (Refer to the basic publication, GROUP 15)
• Remove undercover LH/RH
• Transmission Removal (Refer to page22/19 for MT and page 23/66 for CVT)
• Fuel discharge Prevention (Refer to the basic publication, GROUP 13A)
• Front Exhaust Pipe Installation (Refer to the basic publication, 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)
4. ELC4 solenoid assy (A/T)
5. Inhibitor switch
T
20. Alternator S
21. Knock sensor connector
22. Oil pressure switch
AF
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
R
12. Injector connector

14. Cam angle sensor
15. Harness control
D
16. Harness control to sub-harness sensor

11A ENGINE <IAFM+>
T
AF
R
D
DOIMC11AR11016

ENGINE <IAFM+> 11A
• 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
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
42. Engine insulator mounting bolt
43. Engine mounting bracket
44. Engine mounting stopper
CAUTION :
T
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)
AF
T2: 5.0 - 6.4 kgm (50 - 64 Nm, 36.16 - 46.29 ft.lbs)
T3: 9.0 - 1.1 kgm (90 - 11 Nm, 65.1 - 7.96 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)
R
D

11A ENGINE <IAFM+>
COMPRESSION PRESSURE CHECK

1. Before inspection, check that the engine oil,
starter and battery are normal. In additional,
set the vehicle to the pre-inspection condi-
tion.
2. Disconnect each of the top coil connector.
Symbol Description
A Top coil connector
B Connector pin lock
NOTE:
To remove top coil connector, press pin lock
to disconnect the connector from top coil.
T
AF
R
D
DOIKC11AR08009

ENGINE <IAFM+> 11A
3. To remove the top coil bolt please use the

suitable socket to loosen the bolt. Remove
each of the top coil.
Symbol Description
C Top coil bolt
D Top coil
CAUTION :
During dismantling of the top coil :-
(1) Ensure no force on the top coil during
removal.
(2) No tool is use during removal this way
or it may damage the top coil.
(3) Pull the top coil as illustrated.
T
AF
DOIKC11AR08010
4. Remove each of the spark plugs
Symbol Description
R
E Spark plug.
NOTE :
Please use socket size 16mm.
D
DOIKC11AR08004

11A ENGINE <IAFM+>
5. Disconnect the cranks angle sensor connect-

or.
Symbol Description
Cranks angel sensor con-
F
nector
NOTE :
Doing this will prevent the engine control unit
from carrying out ignition and fuel injection.
T
AF
DOIKC11AR08011
6. Cover the spark plug hole with a shop towel

etc. and after the engine has been cranked,
check that no foreign material is adhering
R
to the shop towel.
Symbol Description
D
G Shop towel
CAUTION :
(1) Keep away from the spark plug hole
when cranking, because there may be
some material such as water, oil, or fuel,
etc., in the cylinder block, these materials
DOIKC11AR08008
will become heated and will gush out
from the spark plug hole, which is very
dangerous.

ENGINE <IAFM+> 11A
7. Set compression gauge to one of the spark

plug holes
Symbol Description
G Shop towel
H Compression gauge
8. Crank the engine with the throttle valve fully
open and measure the compression pressure
Standard value at engine speed of 250 - 400
r/min :
Must be more than 190 psi
DOIKC11AR08005
9. Measure the compression pressure for all the

cylinders, and check that the pressure differ-
ences of the cylinders are below the limit.
Symbol Description
H Compression gauge
1 Depress the accelerator ped-
T al (throttle valve fully open)

Standard value at engine speed of 250 - 400
AF
r/min :
Each cylinder must be more than 190 psi
DOIKC11AR08006
10. If there is a cylinder with compression or a

compression differences are outside the limit,
pour a small amount of engine oil through
R
the spark plug hole, and repeat the opera-

tions in steps (8) and (9).
Limit :
Less than 190 psi
D
Symbol Description
I Pour a small amount of en-
gine oil
DOIKC11AR08007
10.1 If the compression increase after oil is
added, the cause of the malfunction is
a worn or damaged piston ring and / or
cylinder inner surface.
10.2 If the compression does not rise after
oil is added, the cause is a burnt of de-
fective valve seat, or pressure is leaking
from the gasket.
11. Connect the crank angle sensor connector.
12. Install the spark plugs and top coil.

11A ENGINE <IAFM+>
13. Use the PADT–07 to erase the diagnosis codes

NOTE :
This will erase the problem code resulting
from the crank angle sensor being disconnec-
ted.
T
AF
DOIMC054R07056
R
D

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

SERVICE SPECIFICATION ........................................................... 12/2
SEALANTS ............................................................................ 12/2
LUBRICANTS ......................................................................... 12/2
SPECIAL TOOL ......................................................................... 12/3

TOOL .................................................................................. 12/3
OIL FILTER AND OIL PRESSURE SWITCH .......................................... 12/4

REMOVAL AND INSTALLATION ................................................... 12/4
LUBRICATIONS ......................................................................... 12/5

REMOVAL SERVICE POINT ........................................................ 12/5
ON-VEHICLE SERVICE .............................................................. 12/7
T
ENGINE OIL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12/7
12/7
AF
R
D

12 LUBRICATION
/2 GENERAL INFORMATION
GENERAL INFORMATION WCH012GINFO12001
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.
T
• 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
AF
regularly and kept separate from personal clothing.
• Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles
• 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
R
• 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.
D
SPECIFICATIONS WCH012SPECS12001
SERVICE SPECIFICATION
Item Standard value Limit
Oil pressure kPa at idle 29 or more –
at 3,500 r/min 294 – 686 –
SEALANTS
Item Specified sealant Remark
Oil pressure switch 3M ATD Part No. 8660 or equival- –
ent
LUBRICANTS
Engine oil (API classification) SAE 10W/30 or equivalent “SERVICE SJ ” or higher

LUBRICATION 12
SPECIAL TOOL /3
Engine oil quantity, litre (for Oil filter Approx : 0.3 lit (0.32 U.S.qts, 0.26 Imp.qts)
1600cc engine) Total Approx : 3.75 lit (3.95 U.S.qts, 3.26 Imp.qts)
SPECIAL TOOL WCH012STOOL12001
TOOL
Removal and installation of

engine oil filter (When us-
MB991396 Oil filter wrench
ing the oil filter of PW
811577)
DOIIC012R9001
Oil pressure Removal and installation of
T
MD998054
switch wrench oil pressure switch
AF
DOIIC012R01016
R
D

12 LUBRICATION
/4 OIL FILTER AND OIL PRESSURE SWITCH
OIL FILTER AND OIL PRESSURE SWITCH WCH012SASSY12001
T
AF
R
DOIQC012R12001
D
Sealant:
PART NO. MD970389 or equivalent
Engine oil
Removal steps
1. Oil filter
2. Oil seal
4. Oil drain plug
5. Gasket
T1: 1.2-1.6 kgm (12-16 Nm, 8.68-11.57 ft.lbs)

LUBRICATION 12
LUBRICATIONS /5
LUBRICATIONS WCH012SPROC12001

OIL FILTER REPLACEMENT
1. Start the engine and allow it to warm up
until the temperature of the coolant reaches
80 °C (176 °F) to 90 °C (194 °F)
Symbol Description
A Oil filter
DOIMC012R07002
2. Remove the engine oil filler cap at cam cover.

3. Remove the drain plug to drain oil.
CAUTION
Be careful as oil could be hot.
4. Use the following tools to remove the engine
oil filter from the underside of the vehicle.
T • Oil filter number PW811577
Symbol Description
AF
B Special tool MB991396
5. Clean the filter bracket side mounting sur-
DOIMC012R07006 face.
6. Apply a thin film of engine oil to the surface
O-ring of the new oil filter before screwing
it on.
R
Symbol Description
C O-ring
7. Tighten the filter 1 turn after gasket contacts
D
mounting base and use the respective tool

to attach to housing thread and rotate until
filter seal is seated against seal face. Rotate
an additional 90° to 180° to secure.
DOIMC012R07007
8. Install the engine oil filter.

Tightening torque :
When using the oil filter of PW811577 : 1.2-
1.6 kgm (12-16 Nm, 8.68-11.57 ft.lbs)
CAUTION
Oil filter that is insufficiently torqued will
result in oil leaks.
9. Install the drain plug and refill engine oil.
(Refer to GROUP 11 — Oil Filter Removal).
10. Rev the engine 2–3 times, and check to be
DOIMC012L08003 section of the oil filter.

12 LUBRICATION
/6 LUBRICATIONS
OIL PRESSURE CHECK

1. Check engine oil quantity.
2. Remove the oil pressure switch (1) terminal.
3. Use the special tool (oil pressure switch
wrench) to remove the oil pressure switch.
Symbol Description
1 Special tool MD998054
2 Oil pressure switch
CAUTION
Since sealant is applied to the thread of oil
pressure switch, be careful not to damage
the oil pressure switch during removal.
4. Install the oil pressure gauge.
DOIGC012R03011 5. Run the engine.
6. After the engine has been warmed up, check
that oil pressure is within the standard value.
Standard value:
T At idle : 29 kPa (4.13 psi, 8.75 in.Hg) or more

At 3,500 : 294-686 kPa (41.82-97.59 psi,
88.75-207.09 in.Hg) (There must be no oil
AF
leakage)
7. Remove the oil pressure gauge if leak and
replace with a new part.
OIL PRESSURE SWITCH INSTALLATION

1. Apply the specified sealant to the thread of
R
oil pressure switch.

Specified sealant : TB1130 or equivalent.
D
DOIHC012R04006
2. Use the special tool to tighten the oil pres-

sure switch to the specified torque.
Tightening torque :
1.0 kgm (10 Nm, 7.23 ft.lbs)± 0.2 kgm (2 Nm,
1.45 ft.lbs)
Symbol Description
1 Special tool MD998054
2 Oil pressure switch
DOIGC012R03011

LUBRICATION 12
LUBRICATIONS /7
ON-VEHICLE SERVICE WCH012SPROC12002
ENGINE OIL INSPECTION

1. Pull out the level gauge slowly and check
that the oil level is in the illustrated range.
Symbol Description
1 Level gauge
A Good
B Min
C Max
DOIQC012R12002
2. Check that the oil is not excessively dirty, no
coolant or gasoline mixed in and has suffi-
cient viscosity.
ENGINE OIL REPLACEMENT
1. Start the engine and allow it to warm up
until the temperature of the coolant reaches
80 °C (176 °F) to 90 °C (194 °F)
2. Remove the engine oil filler cap.
T 3. Remove the drain plug to drain oil.

CAUTION
AF
Be careful with the hot engine oil.
4. Install a new drain plug so that it faces in the
direction shown in the illustration, and then
tighten the drain plug to the specified
torque.
Symbol Description
R
1 Oil drain plug

2 Gasket (Non-reusable)
T1 3.5 kgm (35 Nm, 25.32 ft.lbs) ±
D
0.5 kgm (5 Nm, 3.62 ft.lbs)
DOIQC012R12003
5. Refill with specified quantity of oil.

Specified Engine Oil (API classification) : Ser-
vice SJ or higher
Total quantity (Includes volume inside oil
filter by using barometric temperature as
shown figure and table).
Engine Oil Quantity

Oil pan Approx : 3.75 litre
Oil Filter Approx: 0.30 litre
Symbol Description
DOIIC012R9003 A Barometric temperature
6. Install the engine oil filter cap.
7. Check oil level.

12 LUBRICATION
/8 LUBRICATIONS
OIL FILTER REPLACEMENT

1. Start the engine and warm up until the
temperature of the coolant reaches 80 °C
(176 °F) to 90 °C (194 °F)
Symbol Description
A Oil filter
DOIMC012R07005
2. Remove the engine oil filler cap at cam cover.

3. Remove the drain plug to drain the engine
oil.
CAUTION
Be careful with hot engine oil.
4. By using special tool, remove the engine oil
T filter as shown in the illustration
Symbol Description
AF
B Special tool MB991396
5. Clean the filter bracket side mounting sur-
DOIMC012R07006 face.
6. Apply a thin film of engine oil to the surface
O-ring of the new oil filter before screwing
it on.
R
Symbol Description
C O-ring
7. Tighten the filter 1 turn after gasket contacts
D
mounting base and use the respective tool

to attach to housing thread and rotate until
filter seal is seated against seal face. Rotate
an additional 90° to 180° to secure.
8. Install the engine oil filter.
DOIMC012R07007 Tightening torque :
When using the oil filter of PW811577 : 1.2-
1.6 kgm (12-16 Nm, 8.68-11.57 ft.lbs)
CAUTION
Oil filter that is insufficiently torqued will
result in oil leaks.
9. Install the drain plug and refill engine oil.
(Refer to Pub. No RDWE-03DA010, GROUP
12).
10. Rev the engine 2–3 times, and check to be
section of the oil filter.

FUEL <CFE> 13A
Content /1
13A FUEL <CFE>

GENERAL INFORMATION ............................................................ 13A/6
OUTLINE OF CHANGES ............................................................. 13A/6
GENERAL ............................................................................. 13A/6
MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM ........................... 13A/7
SPECIAL TOOLS ........................................................................ 13A/8
SERVICE SPECIFICATION ............................................................. 13A/9

SEALANT .............................................................................. 13A/10
TROUBLESHOOTING .................................................................. 13A/10

FREEZE FRAME DATA ............................................................... 13A/10
DISPLAY ITEM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/10
FAIL-SAFE/BACKUP FUNCTION TABLE ........................................... 13A/12
READ OUT OF MALFUNCTION CODE ........................................... 13A/12
PRECAUTION FOR OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/12
TURBO CHARGER PROBLEM SYMPTOM CHECK CHART .................... 13A/15
ENGINE WARNING LAMP .......................................................... 13A/21
ITEMS INDICATED BY THE ENGINE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/21
ENGINE WARNING LAMP INSPECTION ..........................................
SELF-DIAGNOSIS .....................................................................
T
PADT- II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13A/21
13A/21
13A/21
AF
PROBLEM DIAGNOSIS CONTENT CHART- IAFM+/ CFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/22
CFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/31
INSPECTION CHART FOR DIAGNOSIS CODES .................................. 13A/33
CFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/37
INSPECTION PROCEDURE FOR DIAGNOSIS CODES ............................. 13A/38

CAMSHAFT SENSOR ................................................................ 13A/38
R
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/38
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/39
FRONT OXYGEN SENSOR .......................................................... 13A/40
TROUBLESHOOTING OF REAR OXYGEN SENSOR ............................. 13A/43
D

THROTTLE BODY ACTUATOR ..................................................... 13A/46
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/46
TMAP SENSOR (INTAKE AIR TEMPERATURE SENSOR AND VACUUM 13A/51
SENSOR) ...............................................................................
OPERATION INTAKE AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/51
OPERATION FOR VACUUM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/51
COOLANT TEMPERATURE SENSOR .............................................. 13A/54
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/54
ACCELERATOR PEDAL SENSOR ................................................... 13A/57
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/57
OXYGEN CONTROL ................................................................. 13A/59
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/59
INJECTORS ............................................................................ 13A/62
FUEL PUMP RELAY .................................................................. 13A/65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/65

13A FUEL <CFE>
/2 Content

MISFIRE ............................................................................... 13A/67
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/67
KNOCK SENSOR ..................................................................... 13A/70
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/70
CRANKSHAFT SENSOR ............................................................. 13A/73
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/73
TROUBLESHOOTING PROSEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/74
IGNITION COIL ....................................................................... 13A/75
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/75
CATALYTIC SYSTEM ................................................................. 13A/77
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/77
CANNISTER PURGE SOLENOID VALVE .......................................... 13A/79
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/79
ENGINE FAN .......................................................................... 13A/82
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/82
AIR CONDITIONING FAN ........................................................... 13A/84
T
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE SPEED SIGNAL [ CVT ] ...................................................
13A/84
13A/86
13A/87
AF
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/87
BRAKE LIGHT SWITCH (Stop lamp switch) ..................................... 13A/90
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/91
ENGINE SPEED SIGNAL [ CVT ] .................................................... 13A/92
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/92
R
IMMOBILISER ........................................................................ 13A/95

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/95
POWER SUPPLY ...................................................................... 13A/97
D
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/98
CRUISE CONTROL ................................................................... 13A/99
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/99
ENGINE CONTROL UNIT ........................................................... 13A/101
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/101
STARTER CONTROL ................................................................. 13A/103
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/103
SENSOR SUPPLY ..................................................................... 13A/105
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/105
COMPRESSER ........................................................................ 13A/107
MAIN RELAY ......................................................................... 13A/110
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/111
TRANSMISSION CONTROL UNIT (CVT) .......................................... 13A/113
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/113
P/N SWITCH .......................................................................... 13A/115
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/115

FUEL <CFE> 13A
Content /3

PEDAL/BRAKE SWITCH ............................................................. 13A/117
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/118
CAN COMUNICATION .............................................................. 13A/120
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/120
VVT SOLENOID ...................................................................... 13A/122
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/122
BOOST DUMP VALVE (ELECTRONIC CONTROL RELIEF VALVE) ............. 13A/124
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/124
RECIRCULATION PUMP ............................................................. 13A/126
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/126
MAP 2 (MANIFOLD AIR PRESSURE) .............................................. 13A/128
WASTE GATE ......................................................................... 13A/131
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/131
TURBO CHARGER ................................................................... 13A/133
T
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13A/133
13A/134
AF
TROUBLE SYMPTOM ................................................................. 13A/134
INSPECTION CHART FOR TROUBLE SYMPTOMS .............................. 13A/134
PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) ................. 13A/136
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS ......................... 13A/137

INSPECTION PROCEDURE 1 ....................................................... 13A/137
Communication with PADT-II is not possible (Communication with all systems is not 13A/137
R
possible ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PADT-II Communication with engine-ECU is impossible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/138
D
The engine warning lamp does not illuminate right after the ignition switch is turned 13A/139
to the ON position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The engine warning lamp remains illuminating and never goes out. . . . . . . . . . . . . . . . . . 13A/140
No initial combustion (starting impossible) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/141
Initial combustion but no complete combustion (starting impossible) . . . . . . . . . . . . . . . . 13A/142
Takes too long time to start (Incorrect Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/143
Unstable idling (Rough idling, hunting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/144
Idling speed is high (Improper idling speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/145
INSPECTION PROCEDURE 10 ...................................................... 13A/146
Idling speed is low (Improper idling speed ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/146
When the engine is cold, it stalls at idling (Die out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/147
When the engine is hot, it stalls at idling (Die out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/148
The engine stalls when starting the car (Pass out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/149

13A FUEL <CFE>
/4 Content
The engine stalls when decelerating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/150

Hesitation, sag or stumble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/151
The feeling of impact or vibration when accelerating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/152
The feeling of impact of vibration when decelerating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/153
Poor acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/154
Surge ................................................................................. 13A/155
Knocking ............................................................................. 13A/156
Dieseling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/157
Too high CO and HC concentration when idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/158
Low Alternator Output Voltage (Approx 12.3 V ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/159
Power supply system and ignition switch-IG system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/159
T
Fuel pump system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/160
Ignition switch-ST system [M/T] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/161
AF
Ignition switch-ST and inhibitor switch system [CVT] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/162
A/C switch and A/C relay system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/163
Fan motor relay system (Radiator fan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/164
Tank purge valve system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/165
R

PADT-II: Inspection of no initial combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/166
Ignition system: Inspection of no initial combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/167
D

PADT-II: Check if incomplete combustion occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/168
Check if hunting occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/169
PADT-II: Check if idling speed is unstable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/170
PADT-II : Engine stalling inspection when the engine is warmed up and idling . . . . . . . 13A/171
PADT-II: Check if hesitation, sug, stumble or poor acceleration occurs . . . . . . . . . . . . . . . . 13A/172
PADT-II: Check if surge occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/173
Check the engine-ECU power supply and earth circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/174
Check fuel pump motor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/175
Check the fuel pump relay drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/176
Check throttle body actuator (TBA) output circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/177
Check injector control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/178

FUEL <CFE> 13A
Content /5

Check ignition coil and power transistor unit circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/179
DATA LIST ............................................................................... 13A/180

DATA LIST REFERENCE TABLE ..................................................... 13A/180
ACTUATOR TEST ...................................................................... 13A/184

ACTUATOR TEST REFERENCE TABLE ............................................ 13A/184
CHECK AT THE ENGINE-ECU ........................................................ 13A/185

TERMINAL VOLTAGE CHECK CHART ............................................ 13A/186
ENGINE-ECU CONNECTOR TERMINAL ARRANGEMENT ..................... 13A/186
CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMIN- 13A/190
ALS .....................................................................................

COMPONENT LOCATION .......................................................... 13A/191
VIEW LOCATION .................................................................... 13A/192
WASTE GATE CONTROL ........................................................... 13A/193
RELIEVE VALVE (BOOST DUMP VALVE) ......................................... 13A/193
RECIRCULATION PUMP ............................................................. 13A/193
T
OIL CONTROL VALVE ...............................................................
INJECTOR ............................................................................... 13A/195

13A/194
AF
INJECTOR/HIGH-PRESSURE FUEL HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/195
ECU ...................................................................................... 13A/199

R

D
FUEL TANK ............................................................................. 13A/202

PRE REMOVAL SERVICE POINT ................................................... 13A/204

13A FUEL <CFE>
GENERAL INFORMATION WCH13AGINFO11005
OUTLINE OF CHANGES
Due to the introduction of CFE engine variant, the service procedure for the fuel system has been
updated.
GENERAL
A turbocharger consists of a compressor and a turbine connected by a common shaft. The exhaust-
gas-driven turbine supplies the drive energy for the compressor.
Oil control valve
Variable valve timing (VVT), is a generalized term used to describe any mechanism or method that
can alter the shape or timing of a valve lift event within an internal combustion engine. VVT allows
the lift, duration or timing (in various combinations) of the intake valves to be changed while the
engine is in operation.
ECU sends a signal to oil control valve at the end of the camshaft that puts oil pressure behind a lock
pin in the rocker arm, sliding the pin under the spring-loaded slipper follower, locking it to the rocker
arm and forcing the arm to follow the high-rpm cam profile
Wastegates
Wastegate is a valve use to regulate the maximum boost pressure in turbocharger systems by diverting
the exhaust gases away from the turbine wheel to the exhaust.
T
Once a specific boost pressure is achieved, part of the exhaust gas flow is fed around the turbine via
a bypass. The wastegate opens or closes the bypass is operated by a spring-loaded diaphragm using
PWM technique controlled by the Engine ECU.
AF
Dump valve
Dump valve releases pressure in the intake system of a turbocharged vehicle when the throttle is lifted
or closed. The air pressure is released back to the intercooler.
MAP 2 sensor is used and is located upstream from the dump valve to measure the air pressure and
input to the engine control unit (ECU).
Recirculation pump
R
Recirculation pump operates as a turbo cooling timer after engine is turn off. Water-cooled turbochar-
ger turbine housings allow water flow to reduce the heat from exhaust gas.
When the engine is turn off, recirculation pump pumps water from engine block to turbo assembly
for maximum of 600 seconds or when the ECU shut-off.
D
NOTE
Should avoid long idle running (maximum 20 minutes). This is to avoid oil leakage for high pressure
difference between the compressor side and oil pressure side (oil carry over from the bearing housing).

FUEL <CFE> 13A
GENERAL INFORMATION /7
MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM WCH13AGINFO11006
T
AF
R
DOIQC13AR11115
*1 - Map sensor 2 *2 Throttle valve control servo

*2 - Throttle position sensor *3 - Purge control solenoid valve
D
*4 - TMap sensor *5 - Injector

*8 -Camshaft position sensor *9 - Oil control valve
*6 - Engine coolant temperature *7 - Ignition coil, power transistor
sensor *14 - Recirculation pump
*10 - Knock sensor *16 - Waste gate solenoid valve
*11 - Crank angle sensor (PWM)
*12 - Oxygen sensor (front) *17 - Relieve valve (ECRV/ Boost
*13 - Oxygen sensor (rear) valve)
to ⇒Engine ECU⇒ to
• Power supply voltage • Main relay
• Vehicle speed sensor • Fuel pump relay
• Accelerator pedal sensor • A/C power relay
• A/C switch • Engine warning lamp
• Inhibitor switch • Diagnosis signal
• Power steering fluid pressure • Fan motor relay
switch • Alternator G terminal
• Ignition switch — ST
• Ignition switch — IG
• Alternator FR terminal
*15 - Waste gate actuator
*18 - Intercooler

13A FUEL <CFE>
/8 SPECIAL TOOLS
NOTE
The arrow indicated in the system diagram description are as follows;
: Intake flow
: Exhaust flow
: Engine oil flow
: Coolant flow
TOOLS
Vehicle communication
EZT0047 For vehicle diagnosis
interface (VCI)
DOIMC35BR11039
T
AF
VCI manager software
CD for software installa-
and user documentation
tion and user manual
CD
DOIMC35BR11042
R
DLC cable (16-pin OBD Main diagnosis cable to

connector; 1 m) VCI
D
DOIMC35BR11041
For connection between

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

plug adapters power socket
DOIMC35BR11045

FUEL <CFE> 13A
SERVICE SPECIFICATION /9
For software to download-

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

Cable keeper
cable messy
DOIMC35BR11043
Plug adapter for power To be use with power sup-
T
supply ply (EZT 0050)
DOIMC35BR11044
AF
VCI storage case Bag to carry set of PADT-II
R
DOIMC35BR11047
SERVICE SPECIFICATION WCH13ASPECS11003

D
IAFM+
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
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
Vacuum hose discon- 324 - 343 kPa (46.09 - 48.8 psi, 97.81
nection - 103.54 in.Hg) at curb idle
Fuel pressure kPa
Vacuum hose connec- Approx. 265 kPa (37.7 psi, 80 in.Hg)
tion at curb idle

13A FUEL <CFE>
/ 10 TROUBLESHOOTING
Injector coil resistance Ω 13 - 16 Ω (at 20 °C (68 °F))
CFE
Oil control valve resistance Ω 7.2 Ω ± 0.5 Ω (at 20 °C (68 °F))
Relieve Valve (ECRV/BOOST DUMP) 13.2 ± 0.5 Ω
PWM (Waste Gate) 23 ± 1.2 Ω
SEALANT
Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equival-
Drying sealant
threaded portion ent
TROUBLESHOOTING WCH13ASHOOT11194
FREEZE FRAME DATA

When the engine-ECU detects a malfunction and stores a diagnosis code, it also stores a current status
T
of the engine. This function is called "Freeze frame data". By analyzing this "Freeze frame" data with
the PADT.-II, an effective troubleshooting can be performed.
The display items of freeze frame data are shown below.
AF
DISPLAY ITEM LIST
No PADT-II Display Unit / Condition Remarks
*1– Condition in which oxygen sensor sig-
nals are fed back to the engine-ECU for
controlling fuel.
*2– Condition in which fuel is controlled
R
• Open Loop*1
without oxygen sensor signals being fed
• Close Loop*2
back to the engine-ECU because the condi-
1 Fuel system status • Open loop interrupt
tion to shift to the closed loop is not met.
• Open loop error*3
D
*3– Condition of open loop due to system

• Closed loop error*4
failure
*4– Condition of closed loop only using
front oxygen sensor when rear oxygen
sensor is failed
Relative engine load
2 % -
value
Engine coolant temper-
3 °C -
ature
Lambda controller out-
4 % -
put
Fuel mass set point
5 % -
factor
Manifold absolute pres-
6 kPA -
sure
7 Engine speed rpm -
8 Vehicle speed km/h -

FUEL <CFE> 13A
TROUBLESHOOTING / 11

Front Oxygen Sensor
9 OFF / ON -
Status
Rear Oxygen Sensor
10 OFF / ON -
Status
Short Term Secondary
11 % -
O2 Sensor Fuel Trim
Long Term Secondary
12 % -
O2 Sensor Fuel Trim
13 DTC Failure byte - -
controlling fuel.
• Open Loop*1
• Close Loop*2
failure
T *4– Condition of closed loop only using

sensor is failed
AF
15 % -
value
16 °C -
ature
Fuel mass set point
17 % -
R
factor
18 % -
put
D
19 kPA -
sure
Relative throttle posi-
22 % -
tion
Ignition factor applier
23 °CRK -
on first cylinder
• Idle mode, idle contact
closed
• Full load mode
• SAS active
24 Engine status -
• Throttle actuator limp
home mode
• Safety concept activated
• Fuel Shut off mode
Accumulated time of current malfunction
25 Time after start s from time point when malfunction is de-
tected

13A FUEL <CFE>

26 Fault status byte MIL On / MIL Off -
Number of DTC since
27 - -
last DTC clear command
Distance since DTC
28 km -
clearing
Safety level 2 monitor-
29
ing data
30 normal value = 0
ing data
- If display is different from normal value,
Safety level 2 monitor- replace ECU.
31
ing data
32
ing data
FAIL-SAFE/BACKUP FUNCTION TABLE WCH13ASHOOT11195
When the main sensor malfunctions are detected by the self-diagnosis function, the vehicle is controlled
by means of the pre-set control logic to maintain safe conditions for driving.
Malfunction item
Intake air temperature sensor
T
Control contents during malfunction
Controls as if the intake air temperature is 40 °C (104 °F)
AF
Coolant temperature sensor Controls as if the coolant temperature is 80 °C (176 °F)
No increase in fuel injection amount during acceleration due
Throttle body actuator (TBA)
to the throttle position sensor signal
1. Injects fuel into the cylinders in the order 1-3-4-2 with
irregular timing (However, after the ignition switch is
Camshaft sensor
turned to ON, the No. 1 cylinder top dead center is not
R
detected at all)
Combined map & mat sensor Use TPS signal as back-up
Air/Fuel ratio feedback control (closed loop control) is not
D
Oxygen sensor
performed
READ OUT OF MALFUNCTION CODE
PRECAUTION FOR OPERATING
1. When battery voltage is low, no detection
of failure is possible. Be sure to check the
battery for voltage and other conditions be-
fore starting the tests.
2. Connection and disconnection of the PADT–II
should always be made with the ignition
switch in the OFF position.
3. Fault code can only be erased when ignition
switch is in the ON position. After deleting
switch to “OFF” position and wait 30 sec.
before turning ⇒ “ON” the ignition.

FUEL <CFE> 13A
READING PROCEDURE — USING PADT–II

1. Read and make a note of the self-diagnosis
output.
2. Repair the problem location, referring to the
diagnosis chart.
3. After turning the ignition switch once to OFF,
turn it back to ON.
4. Erase the malfunction code.
5. Recheck to be sure that the condition is nor-
mal.
Symbol Description
DOIMC13AR11111 PADT-II vehicle commu-
A
nication interface ( VCI )
B OBD-II cable
C USB cable
NOTE
For details information on the PADT-II, please
refer to the PADT-II User Manual.
T
AF
R
D

13A FUEL <CFE>
NOTE
T
AF
R
D

TURBO CHARGER PROBLEM SYMPTOM CHECK CHART WCH13ASHOOT12001
PROBLEM SYMPTOM
Engine Black Excess- Blue Noise Excess- Excess- Drag or Excess- Dam- Damage
lacks of smoke ive oil smoke ive oil- ive oil- bind in ive rotat- aged turbine POSSIBLE CAUSE SOLUTION
power con- com- turbine rotating ing assy com- wheel
sump- pressor end assy play pressor
tion end wheel
Dirty air cleaner Clean or replace
X X X X X
element filter element
Collapsed or re- Inspect pipe for
stricted air pipe damage or obstruc-
X X X X X
before turbo tion, replace or re-
pair
X
D X X
Pugged crank Clear obstruction
case breathers
Air cleaners ele- Replace, repair or
X
R X X
ment missing
leaking or loose
reconnect air
cleaner element
connection to
turbo
Restricted or Inspect pipe for
damages crossov- damage or obstruc-
X X X X

er pipe turbo to tion, replace or re-
AF
inlet manifold pair
Foreign object inInspect exhaust
exhaust system piping only when
X X X X X X
T X
(from engine, engine is not run-
check engine) ning and cold, re-
move foreign ob-
ject
Turbocharger Inspect all connect-
flanges clamp or ing hardware for
FUEL <CFE>
X X X X X X X X X X X bolt loose damage. Ensure fit

as per installation
instruction
/ 15
13A
PROBLEM SYMPTOM / 16
13A
tion end wheel
Restricted ex- Inspect exhaust
haust system system only when
X engine is cold and
FUEL <CFE>
not running. Re-

move obstruction
Oil lag at start- Inspect lubrication
X X
up system lines, filters
Insufficient lub- and oil for obstruc-
D X X rication tion. Remove ob-
struction
Lubricating oil Replace all filters
R X X
contaminated
with dirt or oth-
and lubricating oil
er material
Improper oil lub- Replace lubrica-
X X rication oil is tion with the cor-
used rect grade
Restricted oil Remove and in-

AF
X X X X feed line spect oil line. Re-
move obstruction
X X
T drain line spect oil line. Re-
move obstruction
Turbocharger Inspect for proper
X X X X seal leakage oil feed/ drain line
installation
Worn journal Contact supplier
X X X X X X X X X X
bearing
PROBLEM SYMPTOM
tion end wheel
Excessive dirt Inspect air cleaner
build-up behind element and in-
turbine wheel take piping for
damage or leak-
X X X X X X X X
age. Replace if
needed. Clean
compressor wheel
and housing
D Excessive carbon Inspect crankcase
build-up on ventilation system
X X X X X X X
compressor
R housing
Too fast acceler- Decrease accelera-
X X ating at initial tion at initial start-
start up
Fuel pump mal- Inspect fuel pump
X X
function for damage

AF
Worn or dam- Inspect injectors
X X
aged injectors for damage
X X Valve timing Adjust if need
X X
T Burned valves Replace if needed
Worn piston Replace if needed
X X
rings
X X Burned pistons Replace if needed
Excessive engine Adjust if needed
X X
FUEL <CFE>
pre-oil
Excessive engine Adjust if needed
X X X X
idle
/ 17
13A
PROBLEM SYMPTOM / 18
13A
tion end wheel
Coked or Contact supplier
X X X X X sludged center
housing
FUEL <CFE>
Oil pump mal- Replace if needed

X
function
Oil filter Replace if needed
X X X X X X X X
plugged
Oil bath air Replace lubricat-
D cleaner. Oil pulling oil with correct
X X X X X
over/ oil viscosity grade
too low or high
R Oil bath air Replace air inlet
cleaner. Air inlet screen
X X X X X
screen restricted
/ dirty air cleaner
Foreign object Inspect air intake
between cleaner piping, remove
X X X X X X X

and turbochar- foreign object
AF
ger
Turbine housing Remove turbine
damaged or re- housing. Inspect
X X X
T X
stricted for cracks or wear.
Replace if needed
Too little warm Extend warm up
X X
up time period
Leaking oil feed Remove and in-
X X line spect oil line. re-
move obstruction
PROBLEM SYMPTOM
tion end wheel
Inlet manifold Remove exhaust
cracked, burned, manifold only
gasket loose, when engine is
blown or missing clod and nor run-
X X X ning, and inspect
for damage to
casting and gas-
kets, replace if
D needed
Oil bath air Replace air inlet
cleaner. Air inlet screen
X X X X X
R screen restricted
/ dirty air cleaner
Boost control Inspect for dam-
malfunction age, leaks, obstruc-
X X X X X X X X X X
wastegate tion. Replace or
repair if needed

AF
T
FUEL <CFE>
/ 19
13A
13A FUEL <CFE>
/ 20
NOTE
T
AF
R
D

FUEL <CFE> 13A
/ 21
ENGINE WARNING LAMP WCH13ASHOOT11197
Among the self-diagnosis items, an engine

warning lamp comes on to notify the driver of
the emission control items when an irregularity
is detected.
Symbol Description
Malfunction indicator lamp
A
(MIL)
ITEMS INDICATED BY THE ENGINE WARNING
LAMP
Front oxygen sensor
Combined map & mat sensor
Crankshaft sensor
Camshaft sensor
Tank purge valve
DOIQC13AR11001
Throttle body actuator
T
Detonation/knock sensor
Ignition coil
Oil control valve
AF
Waste gate
Boost dump
Recirculation pump
Main relay
Starter relay
R
Engine fan
ENGINE WARNING LAMP INSPECTION
1. Check that when the ignition switch is turned ON, the lamp illuminates.
D
2. If the lamp does not illuminate, check for open circuit in harness, blown fuse and blown bulb.
3. If the MIL does not illuminate and no “Clicking” sound of power relay is heard, then ECU or power
supply to ECU is faulty. Check power supply to ECU (blown diode, blown fuse, harness) or replace
ECU.
SELF-DIAGNOSIS
The engine control unit monitors the input/output signals (some signals at all times and the others
under specified time or longer) from when the irregular for a specified time or longer from when the
irregular signal is initially monitored, passing a certain number, the engine control unit judges that
an irregularity has occured, memorizes the malfunction code, and outputs the signal to the self-dia-
gnosis output terminal. There are 16 items connector output terminal. There are 16 pins diagnosis
items, and the diagnosis results can be read out with a PADT- II. Moreover, since memorization of the
malfunction codes is backed up directly by the battery, the diagnosis results are memorized even if
the ignition key is turned off. The malfunction code can only be erased turning the ignition switch
to ON and sending the malfunction code erase signal from the PADT- II to the engine control unit.
PADT- II
Diagnosis Chart
NOTE

13A FUEL <CFE>
/ 22
• Replace the engine control unit if malfunction code is output although the inspection reveals that
there is no problem with the check items.
PROBLEM DIAGNOSIS CONTENT CHART- IAFM+/ CFE
TROUBLE DIAGNOS- DIAGNOSTIC DESCRIP-
PADT-II DISPLAY SYMPTOM DESCRIPTION
CODE IS ITEM TION
Enduring camshaft posi- Camshaft position
Enduring camshaft position
P0011 tion deviation at steady change for diagnosis at
deviation at steady setpoint
setpoint steady setpoint
Camshaft sensor not syn-
Cam_in violation of Intake camshaft position
chronise with crankshaft
crk_ref out of range
P0016 reference
Intake camshaft drift from Intake I one-tooth-off Intake camshaft drift of
position diagnosis position
Camshaft Intake camshaft diagnost-
Intake camshaft diagnostic
ic for engine synchroniza- Plausibility
for engine synchronization
P0340 tion
Intake camshaft synchroniz- Intake camshaft synchron- Intake camshaft syn-
ation diagnosis ization diagnosis chronization loss
P0341
Intake camshaft signal
plausibility
T
Intake camshaft signal Intake camshaft signal
plausibility implausible
Intake camshaft period dia- Intake camshaft period Intake camshaft period
AF
P0344
gnosis diagnosis out of range
Front oxygen sensor heater
P0030 Open circuit
open circuit
Front oxygen sensor heater Upstream oxygen sensor
P0031 Short circuit to gnd
short circuit to ground heater obdi diagnosis
R
Front oxygen sensor heater

P0032 Short circuit to battery
short circuit to battery
Upstream oxygen sensor Lambda sensor heater
P0053 Heater fault
heater fault fault
D
Front oxygen sensor open Open circuit / circuit

P0130
circuit open
Front Oxy-
Front oxygen sensor short Upstream oxygen sensor
P0131 gen Short circuit to ground
circuit to ground signal diagnosis
Sensor
System Front oxygen sensor short
P0132 Short circuit to plus
circuit to battery
Front oxygen sensor circuit Frequency diagnosis up-
P0133 Frequency too small
slow response stream
Front oxygen sensor not Sensor not ready / no
P0134
ready signal
Front oxygen sensor signal Signal excursion not
P0134 Upstream oxygen sensor
excursion not plausible plausible / signal erra
signal diagnosis
Oxygen Sensor Signal dur-
Signal during fuel cut-
P2297 ing fuel Cut Off not Plaus-
off not plausible
ible

FUEL <CFE> 13A
/ 23

CODE IS ITEM TION
Downstream oxygen
Rear oxygen sensor heater
P0036 sensor heater obdi dia-
open circuit
gnosis
Downstream oxygen Downstream oxygen
P0037 sensor heater obdi dia- sensor heater obdi dia-
short circuit to ground
gnosis gnosis
Downstream oxygen
P0038 sensor heater obdi dia-
gnosis
Downstream oxygen sensor Lambda sensor heater
P0054 Heater fault
open circuit fault
Rear Oxy- Rear oxygen sensor open
P0136 gen Open circuit
circuit
Sensor
System Rear oxygen sensor short Downstream oxygen
P0137 Short circuit to ground
circuit to ground sensor signal diagnosis
Rear oxygen sensor short
T
circuit to battery
Downstream Oxygen
Rear Oxygen Sensor Signal Rear Oxygen Sensor Sig-
P2270 Sensor rich voltage
Stuck Lean nal Stuck Rich
AF
threshold check
Downstream Oxygen
Rear oxygen sensor signal signal high during fuel
P2271 Sensor lean voltage
stuck rich cutoff
threshold check
Rear oxygen sensor signal Signal plausibility monit- Signal high during fuel
P2A01
high during fuel cut off oring cutoff
R
Throttle position sensor / Load Sensor Failure or

P0068 TPS diagnosis
Throttle body failure Throttle Failure
AR_RED controller out
D
of max in PL, Lambda

out of MAX
P0093
PUT controller out of
max, Lambda out of
Fuel System Leak Detected MAX,
– Large Leak
Throttle AR_RED controller out
Body Actu- of max in PL, Lambda
ator Load/TPS plausibility out of Min
P0094
check
max, Lambda out of Min
Intake Air System Restric- between Min, MAX
P1121
tion PUT controller out of
max, Lambda between
Min, MAX

13A FUEL <CFE>
/ 24

CODE IS ITEM TION
Throttle Position Sensor
P0101 Load Sensor Failure
failure
TPS diagnosis
P0121 Throttle Failure
Diagnostic
Voltage Throttle Position
P0122 Throttle position sensor 1 low
Sensor 1 Low
Body Actu-
ator Voltage Throttle Position
P0123 position sensor 1 high
Sensor 1 High electric position sensor
Voltage Throttle Position diagnosis
P0222 position sensor 2 low
Sensor 2 Low
Voltage Throttle Position
Sensor 2 High
Throttle Actuator Controller check of lower return error lower return spring
Throttle lower return spring error spring of ETC check
P1588 Body Actu-
ator Throttle Actuator Controller check of upper return error upper return
upper return spring error spring of ETC spring check
P169F
Ambient Pressure adapta-
tion error, Throttle Position
Sensor error
T TPS diagnosis
load sensor or throttle
or AMP failure
AF
P2100 Throttle Throttle Actuator Controller ETC power stage diagnos- open circuit
P2101 Body Actu- short circuit is short circuit
ator Throttle Position Sensor check of lower mechanic- lower position not
P2109
Lower position not Reached al stop of ETC reached
Throttle Actuator Controller ETC power stage diagnos-
P2118 over heat protection
over heat protection is
R
PWM exceeds threshold

Throttle Actuator Controller ETC position controller 1
output position monitoring output monitoring PWM exceeds threshold
D
Throttle 2
P2119 Body Actu-
ator check of lower mechanic- lower mec. stop adapta-
Throttle Actuator Controller al stop of ETC tion outside range
Deviation exceed Threshold ETC control deviation control deviation ex-
diagnosis ceeds threshold
Throttle/Pedal Ratio
Ratio check
Throttle check
Throttle/Pedal Position TPS1 plaus error
P2135 Body Actu- TPS – MAF plausibility
plausibility
ator check TPS2 plaus error
TPS rationality check TPS ratio error
Throttle Position Sensor check of upper mechanic- upper position not
P2163
Upper Position not Reached al stop of ETC reached
Throttle Throttle Position Sensor
check of adaptation con- adaptation conditions
P2176 Body Actu- Adaptation Exceed
dition exceeded
ator Threshold
Limp-home Adaptation check of TPS limp home limp-home adaptation
P2176
Outside Range position outside range

FUEL <CFE> 13A
/ 25

CODE IS ITEM TION
of min in PL, Lambda
between Min, MAX
P2279 Intake Air System Leak
min, Lambda between
Min, MAX
Air Flow Restriction/Air Leak
Between Air Filter and MAF
controller not enable
P2280
Throttle Between Air Filter and MAF max, Lambda controller
Load/TPS plausibility not enable
Body Actu-
check
ator AR_RED controller out
of min in PL, Lambda out
of Max
P2281
Air Leak Between MAF and
Throttle Body
T of Min
AF
min, Lambda out of
MAX
min, Lambda out of Min
Throttle
R
Air Leak Between Throttle Load/TPS plausibility controller not enable

P2282 Body Actu-
Body and Intake Valves check PUT controller out of
ator
min, Lambda controller
not enable
D
Manifold air pressure sensor Signal line short to

P0102
short circuit to ground Manifold air pressure ground
Manifold air pressure sensor sensor diagnosis Signal line short to bat-
P0103
short circuit to battery tery voltage
Manifold absolute pressure Manifold pressure plaus- Manifold pressure not
P0106
not plausible (MAP) ibility plausible
Intake Air Temperature
P0111 TMap TIA stuck signal diagnosis Stuck TIA signal
Sensor plausibility
Sensor
Signal short circuit to
P0112 Sensor 1 short Circuit to
TIA signal electrical dia- ground
ground
gnosis
P0113 Signal open circuit
Sensor 1 open Circuit
Ambient pressure plausibil- Ambient pressure plausib- Ambient pressure not
P2227
ity ility plausible

13A FUEL <CFE>
/ 26

CODE IS ITEM TION
Coolant temperature sensor
P0117 Coolant Short circuit to ground
Temperat-
Coolant temperature sensor Coolant temperature sig- Short circuit to vbatt or
P0118 ure
open circuit nal range diagnosis open circuit
Sensor
P0119 System Coolant temperature signal Coolant temperature
gradient error signal gradient error
P0122 Pedal voltage sensor 1 low Pedal Voltage 1 low
P0123 Accelerat- Pedal voltage sensor 1 high Pvs_1 out of range check Pedal Voltage 1 high
or Pedal
P0222 Sensor Pedal voltage sensor 2 low Pvs_2 out of range check Pedal Voltage 2 low
P0223 Pedal voltage sensor 2 high Pedal Voltage 2 high
Fuel system diagnosis for Maximum limit of
Maximum limit of Lambda
lambda controller monit- lambda controller is
controller is reached
oring reached
P0171
Fuel system diagnosis for
Maximum limit of adapta- Maximum limit of adapt-
lambda adaptation mon-
tion value was reached ation value was reached
Oxygen itoring
Control
Minimum limit of Lambda
T
lambda controller monit-
oring
Minimum limit of
lambda controller is
reached
AF
P0172
Minimum limit of adapta- Minimum limit of adapt-
itoring
Injector Circuit/Open – Cylin-
P0201 Cylinder 1 open circuit
der 1
R

der 2 Injection valve diagnostic
Injector Circuit/Open – Cylin- - open circuit
der 3
D

der 4
Cylinder 1 Injector short cir- Injection valve diagnostic Cylinder 1 short circuit
P0261
cuit to ground - short circuit ground ground
P0262
Injector cuit to battery - short circuit plus plus
System Cylinder 2 Injector short cir- Injection valve diagnostic Cylinder 2 short circuit
P0264
P0265
cuit to battery - short circuit plus plus
P0267
P0268
P0270
P0271

FUEL <CFE> 13A
/ 27

CODE IS ITEM TION
Fuel Pump Relay Open Cir-
P025A Open circuit
cuit
Fuel
Fuel Pump Relay Short Cir- Fuel pump electrical dia-
P025C Pump Re- Short circuit to ground
cuit to Ground gnostic
lay
Fuel Pump Relay Short Cir-
P025D Short circuit to battery
cuit to Battery
Random/multiple cylinder Random or multiple mis-
P0300 Plausibility
misfire detected fire diagnosis
P0301 Cylinder 1 misfire detected Misfire on cylinder 1
Misfire
Misfire diagnosis
Knock acquisition chain
P0324 Knock control system error Knck spi failure
diagnosis
Knock
Basis knock signal dia-
P0325 Sensor Knock sensor error Knck sensor basic failure
gnosis
P0326
System
Relative knock signal dia-
gnosis
T
Relative knock signal
diagnosis
Knck sensor relative fail-
ure
AF
Crankshaft sensor failure Crankshaft sensor failure Crankshaft sensor failure
P0335 open or short circuit dia- open or short circuit dia- open or short crk_oc cir-
gnosis gnosis cuit
Crankshaft signal miss-
Crankshaft signal missing Crankshaft signal missing
ing
Crank- Crankshaft signal implaus- Crankshaft signal implaus- Crankshaft signal im-
R
shaft ible ible plausible

Sensor Crankshaft loss of synchron- Crankshaft loss of syn- Crankshaft synchroniza-
P0336
ization diagnosis chronization diagnosis tion lost
D
Crankshaft tooth number Crankshaft tooth number Wrong crankshaft tooth

error diagnosis error diagnosis number
Crankshaft tooth period Crankshaft tooth period Crankshaft tooth period
diagnosis diagnosis out of range

13A FUEL <CFE>
/ 28

CODE IS ITEM TION
P0351 Ignition Coil 1 open circuit
Open circuit
Ignition Coil 1 short circuit
to ground
to battery
P2303 Ignition Ignition Coil 3 short circuit Short circuit to ground

Coil Sys- to ground Ignition Diagnosis
tem Ignition Coil 3 short circuit
to battery
to ground
to battery
P2309
to ground
T Short circuit to ground

AF
to battery
Catalyst Catalyst system efficiency Catalyst efficiency dia-
P0420 Catalyst efficiency
Converter below threshold gnosis
Canister purge solenoid Cannister purge Solenoid Present electrical cps
P0444
valve Open Circuit diagnostic oc failure open circuit
R
Cannister Canister Purge Solenoid Present electrical cps

Cannister purge Solenoid
P0458 purge Diagnostic Short Circuit to failure short circuit to
diagnostic scg
Solenoid Ground ground
Valve
D
Canister Purge Solenoid Present electrical cps

P0459 Diagnostic Short Circuit to failure short circuit to
diagnostic scp
Battery battery
P0480 Fan 1 Open circuit Open circuit Fan 1 Open circuit
Fan 1 Short circuit To Fan 1 Short circuit To
P0691 Engine Short circuit to ground
ground ground
fan
Fan 1 Short circuit To Bat- Fan 1 Short circuit To
tery Battery
Electrical diagnosis of vs
P0500 Vehicle Vehicle speed sensor Vs sensor defective
sensor
speed
sensor Vehicle speed correlation Electrical diagnosis of vs
P215A Vs can not valid
not valid can
Brake
BLS-BTS check detected
P0504 light Brake Switch Error Plausibility
error
switch

FUEL <CFE> 13A
/ 29

CODE IS ITEM TION
Engine speed at idle is be-
Index for diagnostic isc
P0506 low calculated idle speed Present isc_low failure
Engine too low
target
speed
sensor Engine speed at idle is
P0507 above calculated idle speed Present isc_high failure
too high
target
immobilizer failure due
P0513 Immobilizer locked to wrong authentication Wrong transponder
Immob- process
ilzer immobilizer failure due
Communication with
P0633 to no communication Transponder missing
transponder missing
with transponder
P0562 Battery voltage too low Battery voltage too low Battery voltage too low
P0563 Power Battery voltage too high Battery voltage too high Battery voltage too high
Supply Battery voltage too high Battery voltage too high Battery voltage too high
P1793
Battery voltage too low Battery voltage too low Battery voltage too low
P0564
gnosis - accelerate
Cruise control device dia-
T
Cruise control device dia- Cruise control device dia-
gnosis
Cruise control device
diagnosis
Cruise control device
AF
P0567
gnosis - ON/OFF diagnosis
Auto Cruise control device dia- Cruise control device
P0568
Cruise gnosis - resume Cruise control device dia- switch stuck
Cruise control device diagnosis Cruise control device
P0569
gnosis - deccelerate diagnosis
Cruise control device dia- Cruise control device Im-
R
P0585
gnosis plausible
ECU Warm-reset diagnos- ECU Warm-reset diagnos-
P0604 ECU Warm Reset
is is
D
P0606 ECU Internal Fault SPI Bus communication ECU Monitoring

P060A ECU Internal Fault - General General monitoring General monitoring
ECU Internal Fault - Pro- Processor monitoring
P060C ECU Monitoring
cessor monitoring failure
ECU
Actual or requested
Torque intervention for Torque intervention for
P061A torque higher than al-
safety active satety active
lowed limit
P061B Torque monitoring Torque monitoring Torque monitoring
Internal Control Module
P061C N_LIM monitoring ECU internal Monitoring
Engine RPM Performance
P0615 Starter relay open circuit Open circuit
Starter relay short circuit to
P0616 Starter Short circuit to ground
ground Starter relay
Control
battery

13A FUEL <CFE>
/ 30

CODE IS ITEM TION
Sensor Reference Voltage
P0642 Vcc low diagnostic Supply Voltage low
“A” Circuit Low
P0643 Vcc high diagnostic Supply Voltage high
Supply “A” Circuit High
Voltage Sensor Reference Voltage
“B” Circuit Low
“B” Circuit High
Air condition clutch, open
P0645 Open circuit
circuit
Air cond Air condition clutch, short Air conditioning com-
clutch circuit to ground pressor diagnosis
Air condition clutch, short
circuit to battery
Main relay input Open Cir- Main relay input OL elec- Main relay input Open
P0685
cuit trical diagnosis Circuit
P0686
Main relay input Short cir-
cuit to Ground
Main relay input Short cir-
T
Main relay input SCG
electrical diagnosis
Main relay input SCP
Main relay input Short
circuit to Ground
Main relay input Short
AF
P0687
Main re- cuit to Battery electrical diagnosis circuit to Battery
lay Main relay ON output dia- Main relay ON output Main relay ON output
P0689
gnosis plausibility diagnosis plausibility diagnosis plausibility
Main relay OFF output dia- Main relay OFF output Main relay OFF output
P0690
Main relay switch ON too Main relay switch ON too Main relay switch ON
R
P2510
slow slow too slow
Transmission control unit Transmission control unit
P0700 TCU Transmission Limp Home
limp home diagnosis limp home diagnosis
D
Hard wired P/N switch

P0850 P/N switch P/N switch plausibility Plausible value
diagnosis
Pedal / Brake Pedal Position/Accel-
P2299 Brake erator Pedal Position Incom- Plausibilty brake error Plausibility
Switch patible

FUEL <CFE> 13A
/ 31

CODE IS ITEM TION
U0073 CAN diagnosis - buss off Can diagnosis Can bus off
Error in the respective
CAN diagnosis - lost commu- control unit (cu) commu-
U0100 Can diagnosis for ecu
nication with ECU nicating on the can-hs
bus
U0101 Can diagnosis for tcu
CAN com- nication with TCU nicating on the can-hs
munica- bus
tion Error in the respective
U0121 Can diagnosis for abs
nication with ABS/ESP nicating on the can-hs
bus
U0140 Can diagnosis for icu
nication with meter cluster nicating on the can-hs
bus
CFE
TROUBLE DIAGNOS-
T DIAGNOSTIC DESCRIP-
AF
CODE IS ITEM TION
Camshaft Control Open Cir-
P0075 Open Circuit
cuit
VVT Camshaft Control Short Cir- Failure at VVT solenoide
P0076 Short Circuit to Ground
Solenoid cuit to Ground valve
Camshaft Control Short Cir-
R
P0077 Short Circuit to Plus

cuit to Battery
Boost Bypass Valve Stuck Plausibility stuck close
P1427 Plausibility stuck close
Close diagnosis
D
Boost Bypass Valve Stuck Plausibility stuck open

P1428 Plausibility stuch open
Open diagnosis
RCL actuator electrical
Boost Bypass Valve Open
P1430 power stage diagnosis Open Circuit
Circuit
Boost for open circuit
Dump RCL actuator electrical
Valve Boost Bypass Valve short power stage diagnosis
P1431 Short Circuit to Ground
Circuit to ground for short circuit to
ground
RCL actuator electrical
Boost Bypass Valve short power stage diagnosis
Circuit to battery for short circuit to posit-
ive
Coolant Water Pump Con-
P2600 Open circuit
trol Open circuit
Coolant
P2602 Water Coolant water pump Short circuit to ground
trol short circuit to ground
Pump
trol short circuit to battery

13A FUEL <CFE>
/ 32

CODE IS ITEM TION
Basic charge air pressure
Basic Air Pressure Adapta- Adaptation reached high
P1251 adaptation diagnosis for
tion High Threshold threshold
high threshold
Basic charge air pressure
Basic Air Pressure Adapta- Adaptation reached low
P1252 adaptation diagnosis for
tion Low Threshold threshold
low threshold
Pressure Upstream Throttle
P012B PUT plausibility Plausability
MAP Sensor plausibility
sensor 2 Diagnosis for pressure
upstream throttle sensor
P012C Sensor Short Circuit to Short circuit to ground
for short circuit to
Ground
ground
Diagnosis for pressure
upstream throttle sensor
P012D Sensor Short Circuit to Bat- Short circuit to plus
for short circuit to posit-
tery
ive
Waste gate electrical
P0243
Wastegate Actuator Open
Circuit
T
power stage diagnosis
for open circuit
Open circuit
AF
Wastegate Actuator Circuit power stage diagnosis
to ground for short circuit to
ground
Waste
gate
Wastegate Actuator Circuit power stage diagnosis
to battery for short circuit to posit-
R
ive
Waste gate diagnosis for Waste gate diagnosis for
P1172 Wastegate Adaptation
high speed high speed
D
Waste gate diagnosis for Waste gate diagnosis for

low speed low speed
Wasteg-
ate / Turbocharger/Supercharger Diagnosis for charge air Charge Air Pressure too
P0234
Turbo Overboost Condition pressure too high high
charger
Turbochar- Diagnosis Turbocharger/Su- Diagnosis for basic
Basic Charge air Pressure
ger / In- percharger Underboost charge air pressure too
too Low
P0299 take Sys- Condition low
tem Leak- Turbocharger/Supercharger Diagnosis for charge air Charge Air Pressure too
ing Underboost Condition pressure too low Low
Turbo turbo charger speed too Turbo charger speed ex-
P2578 Turbocharger Overspeed
charger high ceed limit

FUEL <CFE> 13A
/ 33
INSPECTION CHART FOR DIAGNOSIS CODES WCH13ASHOOT11199
Fault code Diagnosis items Reference page

P0011
P0016
P0340 Camshaft Sensor 13A/38
P0341
P0344
P0030
P0031
P0032
P0130
P0131
Front Oxygen Sensor System 13A/40
P0132
P0133
P0134
P0053
P2297
P0036
P0037
T
AF
P0038
P0136
P0137
Rear Oxygen Sensor System 13A/43
P0138
P2A01
R
P0054
P2270
P2271
D

13A FUEL <CFE>
/ 34

P0093
P0094
P0068
P1121
P2176
P0101
P0121
P0122
P0123
P0222
P0223
P1588
P169F Throttle Body Actuator System 13A/46
P2100
P2101
P2109
P2118
P2119
T
AF
P2135
P2163
P2176
P2279
P2280
R
P2281
P2282
P0102
D
P0103
P0106
P0111 TMap Sensor 13A/51
P0112
P0113
P2227
P0117
P0118 Coolant Temperature Sensor System 13A/54
P0119
P0122
P0123
Accelerator Pedal Sensor 13A/57
P0222
P0223
P0171
Oxygen Control 13A/59
P0172

FUEL <CFE> 13A
/ 35

P0201
P0202
P0203
P0204
P0261
P0262
Injectors System 13A/62
P0264
P0265
P0267
P0268
P0270
P0271
P025A
P025C Fuel Pump Relay 13A/65
P025D
P0300
P0301
P0302 Misfire
T 13A/67
AF
P0303
P0304
P0324
P0325 Knock Sensor System 13A/70
P0326
R
P0335
Crankshaft Sensor 13A/73
P0336
P0351
D
P0352
P0353
P0354
P2300
P2301
Ignition Coil System 13A/75
P2303
P2304
P2306
P2307
P2309
P2310
P0420 Catalytic Converter 13A/77
P0444
P0458 Cannister Purge Solenoid Valve 13A/79
P0459

13A FUEL <CFE>
/ 36

P0480
P0691 Engine Fan 13A/82
P0692
P0481
P0593 Engine Fan 2 13A/84
P0594
P0500
Vehicle Speed Signal (CVT) 13A/87
P215A
P0504 Brake Light Switch 13A/90
P0506
Engine Speed Signal (CVT) 13A/92
P0507
P0513
Immobilizer 13A/95
P0633
P0562
P0563 Power Engine Control Unit 13A/97
P1793
P0564
P0567
T
AF
P0568 Auto cruise 13A/99
P0569
P0585
P0604
P0606
R
P060A
P060C Engine Control Unit 13A/101
P061A
D
P061B
P061C
P0615
P0616 Starter Control 13A/103
P0617
P0642
P0643
Sensor Supply 13A/105
P0652
P0653
P0645
P0646 Compresser 13A/107
P0647

FUEL <CFE> 13A
/ 37

P0685
P0686
P0687
Main Relay 13A/110
P0689
P0690
P2510
P0700 Automatic Transmission Control Unit 13A/113
P0850 P / N Switch 13A/115
P2299 Pedal / Brake Switch 13A/117
U0073
U0100
U0101 CAN Interface 13A/120
U0121
U0140
CFE
Fault code
P0660
Diagnosis items
T Reference page
AF
P0661 VVT Solenoid 13A/122
P0662
P1427
P1428
P1430 Boost Dump Valve 13A/124
P1431
R
P1432
P2600
P2602 Recirculation Pump 13A/126
D
P2603
P1251
P1252
P012B MAP sensor 2 13A/128
P012C
P012D
P0243
P0245
P0246 Waste gate 13A/131
P1172
P1173
P0234
P0299 Turbo charger 13A/133
P2578

13A FUEL <CFE>
/ 38 INSPECTION PROCEDURE FOR DIAGNOSIS CODES
INSPECTION PROCEDURE FOR DIAGNOSIS CODES WCH13ASHOOT11200
CAMSHAFT SENSOR
T
AF
R
DOIQC13AR11117
D
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.

FUEL <CFE> 13A
INSPECTION PROCEDURE FOR DIAGNOSIS CODES / 39
Check condi-
Fault codes PADT-II Display Symptom description Range of Check
tion
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
T
diagnosis out of range ning
TROUBLESHOOTING PROCEDURE
AF
R
D
DOIQC13AR11118

13A FUEL <CFE>
FRONT OXYGEN SENSOR WCH13ASHOOT11201
T
AF
R
D
DOIQC13AR11119
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.

FUEL <CFE> 13A
Fault
PADT-II Display Symptom description Range of Check Check condition
Codes
Front oxygen sensor heat- • 3 minutes have
P0030 Open circuit Engine is running
er open circuit passed after
Front oxygen sensor heat- engine was
P0031 Short circuit to GND started. Engine is running
er short circuit to ground
• Engine coolant
Front oxygen sensor heat- Short circuit to bat-
P0032 temperature is Engine is running
er short circuit to battery tery
approx. 80 °C
Front Oxygen Sensor Open Open circuit / Circuit (176 °F) or
P0130 Engine is running
Circuit Open more.
Front Oxygen Sensor Short Short circuit to • Intake air tem-
Circuit to Ground ground perature is 20 -
Front Oxygen Sensor Short 50 °C (68 -122
P0132 Short circuit to plus °F) Engine is running
Circuit to Battery
• Engine speed is
Front oxygen Sensor Cir-
P0133 Frequency too small approx. 2000 - Engine is running
cuit Slow Response
3000 r/min
Front Oxygen Sensor not Sensor not ready / • Vehicle is mov- Engine is running
Ready No signal ing at constant
P0134
Front Oxygen Sensor Sig-
nal Excursion Not Plausible
T
Signal excursion not
plausible / Signal er-
ror
speed on a
flat, level road
surface .
Engine is running
AF
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
R
for 30 seconds
(does not cross
0.6 V for 30
seconds).
D
• 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 mv

13A FUEL <CFE>

Actuator Front Oxygen Sensor Front Oxygen controller =
Idle speed
Test Heater ON
T
AF
R
D
DOIQC13AR11120

FUEL <CFE> 13A
TROUBLESHOOTING OF REAR OXYGEN SENSOR WCH13ASHOOT11202
T
AF
R
D
DOIQC13AR11121
OPERATION

13A FUEL <CFE>
Fault Symptom descrip-

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

oxygen sensor
(rear) output
voltage is 0.08 V
D
or less.
• The oxygen
Rear oxygen sensor signal Signal high during sensor (rear) out-
P2A01 put voltage is 0.5 Engine is running
high during fuel cut off fuel cut off
V or more.
• The above condi-
tions continue
for a continuous
period of 5
seconds.
Ignition On ± 49974.7 mv
Data List Rear Oxygen Sensor Voltage
Engine runs at idle 180 ~ 401
Rear Oxygen controller
Actuator Test Rear Oxygen Sensor Heater Idling speed
= ON

FUEL <CFE> 13A
T
AF
R
DOIQC13AR11122
D

13A FUEL <CFE>
THROTTLE BODY ACTUATOR WCH13ASHOOT11203
T
AF
R
DOINH13AR11008
OPERATION
The throttle body actuator converts the throttle position opening into a voltage signal and inputs it
D
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.

FUEL <CFE> 13A
Check condi-
Fault codes PADT-II Display Symptom Description Range of Check
tion
Throttle position sensor Load Sensor Failure or Engine is run-
P0068
/ Throttle body failure Throttle Failure ning
Engine is run-
ning
Fuel System Leak Detec- out of MAX
P0093
ted – Large Leak PUT controller out of
Engine is run-
max, Lambda out of
ning
MAX,
Engine is run-
ning
Fuel System Leak Detec- out of Min
P0094
Engine is run-
max, Lambda out of
ning
Min
Throttle Position Sensor Engine is run-
failure ning
• Ignition switch: ON
T
P0121 Throttle Failure • Excluding 60
Diagnostic ning
seconds after the
Voltage Throttle Posi- Engine is run-
P0122 position sensor 1 low ignition switch is
AF
tion Sensor 1 Low ning
turned to ON or
Voltage Throttle Posi- immediately after Engine is run-
tion Sensor 1 High the engine starts. ning
Voltage Throttle Posi- Set conditions: Engine is run-
tion Sensor 2 Low • When the idle ning
Voltage Throttle Posi- switch out is ON, Engine is run-
R
P0223 position sensor 2 high sensor output

tion Sensor 2 High ning
voltage is 2 V or
more for 4 Engine is run-
seconds. ning
D
Intake Air System Restric- between Min, MAX • Sensor output

P1121
tion PUT controller out of voltage is 0.2 V or Engine is run-
max, Lambda between less for 4 seconds. ning
Min, MAX
Throttle Actuator Con-
error lower return Engine is run-
troller lower return
spring check ning
spring error
P1588
error upper return Engine is run-
troller upper return
spring check ning
spring error
Throttle Actuator Con- Engine is run-
P2100 open circuit
troller open circuit ning
P2101 short circuit
troller short circuit ning
lower position not Engine is run-
P2109 Lower position not
reached ning
Reached
Engine is run-
ning

13A FUEL <CFE>
Check condi-
tion
troller over heat protec-
tion
PWM exceeds Engine is run-
Throttle Actuator Con- threshold 1 ning
troller output position
monitoring PWM exceeds Engine is run-
threshold 2 ning
P2119
lower mec. stop adapt- Engine is run-
Throttle Actuator Con- ation outside range ning
troller Deviation exceed
Threshold control deviation ex- Engine is run-
ceeds threshold ning
Throttle/Pedal Ratio Engine is run-
check ning
Engine is run-
TPS1 plaus error
Throttle/Pedal Position ning
P2135
plausibility Engine is run-
TPS2 plaus error
T
TPS ratio error
ning
Engine is run-
ning
AF
upper position not Engine is run-
P2163 Upper Position not
reached ning
Reached
adaptation conditions Engine is run-
P2176 Adaptation Exceed
exceeded ning
Threshold
R

Engine is run-
ning
between Min, MAX
D

Engine is run-
min, Lambda between
ning
Min, MAX
Air Flow Restriction/Air AR_RED controller out
Engine is run-
Leak Between Air Filter of max in PL, Lambda
ning
and MAF controller not enable
P2280
Air Flow Restriction/Air PUT controller out of
Engine is run-
Leak Between Air Filter max, Lambda control-
ning
and MAF ler not enable
Air Leak Between MAF Engine is run-
and Throttle Body ning
out of Max
P2281 of min in PL, Lambda
out of Min
min, Lambda out of
MAX

FUEL <CFE> 13A
Check condi-
tion
min, Lambda out of
Min
Engine is run-
Air Leak Between ning
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
Function PADT-II Display Check condition Standard value
Throttle Position
Idle speed 5.49 %
Signal (TPS)
TBA Adaptation Idle speed Done
Data List Additive throttle
area adaptation
Mulplicative
Engine run at
T ±29.29 kg/cm² (416.68 psi, 2.93 MPa)
AF
idle
throttle area adapt- ± 50.0%
ation
Throttle position signal
Warmed up engine for few
value increase (0~100%)
Actuator Test Throttle Valve minutes and set engine at id-
as the accelerator pedal
R
ling
is pressed
D

13A FUEL <CFE>
T
AF
R
DOINH13AR11009
D

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

WCH13ASHOOT11204
T
AF
R
DOIQC13AR11125
OPERATION INTAKE AIR TEMPERATURE SENSOR

D
The intake air temperature sensor, which is integrated with the Tmap sensor converts the engine intake
air temperature into a voltage and inputs it to the engine control unit, which then corrects the fuel
injection rate, etc., based on input signal.
The 5 power in the engine control unit is supplied via a resistor in the unit to the intake air temperature
sensor. Via the sensor which is a kind of resistor, it is then earthed in the engine control unit. The intake
air temperature sensor resistor has such characteristic that its resistance decreases as the intake air
temperature rises.
The intake air temperature sensor terminal voltage increases or decreases. Therefore, the intake air
temperature sensor terminal voltage changes with the intake air temperature, decreasing as the
temperature rises.
OPERATION FOR VACUUM SENSOR
The vacuum sensor which is integrated in the Tmap sensor converts the air intake plenum pressure
to a voltage value and inputs it to the engine control unit. The engine control unit uses this signal
and the engine rpm to calculate the basic fuel injection timing.
5V of power is supplied to the vacuum sensor from the engine control unit, and the sensor circuit
earth is located in the engine control unit. The vacuum sensor output voltage is proportioned to the
air intake plenum pressure and sent to the engine control unit.

13A FUEL <CFE>
Check condi-
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
T • The output voltage

of the boost sensor
is 0.2 V or less for
AF
4 seconds. (This
correspond to the
absolute manifold
pressure of 4.9
kPa (0.7 psi, 1.48
in.Hg) or less).
R
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-
D
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.

FUEL <CFE> 13A

Intake Air Temper- 33 °C (91.4 °F) ( 0 °C (32 °F) ~ 100 °C (212
Ign on
ature °F))
Data list Ign on 1010 Hpa
Intake manifold
pressure Engine runs at
410 Hpa
idle
T
AF
R
D
DOIQC13AR11126

13A FUEL <CFE>
COOLANT TEMPERATURE SENSOR WCH13ASHOOT11205
T
AF
R
DOIQC13AR11127
OPERATION
The coolant temperature sensor converts the coolant temperature into a voltage and inputs it to the
D
engine control unit, which then control fuel injection rate and fast idle speed when the engine is cold,
based on the input signal.
The 5V power in the engine control unit is supplied via a resistor in the unit to the coolant temperature
sensor. Via the sensor which is a kind of resistor, it is then earthed in the engine control unit. The
coolant temperature sensor resistor has such characteristic that its resistance decreases as the coolant
temperature rises.
The coolant temperature sensor terminal voltage increases or decreases. Therefore, the coolant tem-
perature sensor terminal voltage changes with the coolant temperature, decreasing as the temperature
rises.

FUEL <CFE> 13A
Check condi-
tion
Coolant Temperature • Ignition switch: ON
Short circuit to Engine is run-
P0117 Sensor Short Circuit to • Excluding 60
ground ning
Ground seconds after the
Coolant Temperature Short circuit to Vbatt ignition switch is Engine is run-
P0118 turned to ON or
Sensor Open Circuit or Open circuit ning
immediately after
the engine starts.
Set conditions:
• Sensor output
voltage is 4.6 V or
more (correspond-
ing to an engine
coolant temperat-
ure of -45 °C (-49
°F) or less) for 4
seconds.
• Sensor output
voltage is 0.1 V or
T less for (corres-

ponding to an en-
gine coolant tem-
AF
perature of 140 °C
(284 °F) or more)
for 4 seconds.
Coolant Temperature Coolant temperature • Engine speed is ap- Engine is run-
P0119 prox. 500 r/min or
Signal Gradient Error signal gradient error ning
R
more.
Set conditions:
• The sensor output
voltage increases
D
from 1.6 V or less

(corresponding to
an engine coolant
temperature of 40
°C (104 °F) or
more) to 1.6 V or
more (correspond-
ing to an engine
coolant temperat-
ure of 40 °C (104
°F) or less)
• After this, the
sensor output
voltage is 1.6 V or
more for 5
minutes.

13A FUEL <CFE>

Engine temperature Engine runs at idle 89 °C (192.2 °F)
Data List Engine start temperat- 29 °C (84.2 °F) ( 0 °C (32 °F) ~
Engine runs at idle
ure 100 °C (212 °F))
T
AF
R
D
DOIQC13AR11128

FUEL <CFE> 13A
ACCELERATOR PEDAL SENSOR WCH13ASHOOT11206
T
AF
R
DOIQC13AR11129
OPERATION
The accelerator pedal sensor converts the changes (increase or decrease) of the depressed pedal into
D
pulse signal and inputs these signals to the engine control unit. The engine conrol unit determines
how much the changes of the depressed pedal.
5V power is supplied to the accelerator pedal sensor from the engine control unit, and the earth
connection is positioned to engine control unit.

13A FUEL <CFE>

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

FUEL <CFE> 13A
T
AF
R
DOIQC13AR11130
OXYGEN CONTROL WCH13ASHOOT11207

D
DOIQC13AR11131
OPERATION
The oxygen control which is integrated with oxygen sensor, works by detecting the concentration of
oxygen in exhaust gas; it converts those data to voltage, and inputs the resulting signals to the engine
control unit.

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

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

FUEL <CFE> 13A
T
AF
R
D
DOIQC13AR11132

13A FUEL <CFE>
INJECTORS WCH13ASHOOT11208
T
AF
R
D
DOIQC13AR11133
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.

FUEL <CFE> 13A
Fault
PADT-II Display Symptom description Range of Check Check Condition
Code
Injector Cir-
Injection valve dia-
P0201 cuit/Open – Cylinder Engine is running
gnostic - open circuit
1
Injector Cir-
2
Injector Cir-
3
Injector Cir-
4 • Engine speed is ap-
Cylinder 1 Injector Injection valve dia- prox. 500-1000
P0261 short circuit to gnostic - short circuit r/min Engine is running
ground ground • The throttle posi-
Cylinder 1 Injector Injection valve dia- tion sensor output
P0262 short circuit to bat- gnostic - short circuit voltage is 1.15 V or Engine is running
tery
Cylinder 2 Injector
plus
T •
less
Actuator test by
PDT-2000 is not
AF
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.
R
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
D
tery plus
ground ground
tery plus
Ign on 0 MS
Data List Injection Time
Engine runs at idle 4.3 ~ 4.43 MS
Injector 1 Check cylinders
• Warmed up the en-
Injector 2 which affect idling,
gine for few minutes
Actuator test Idling condition be-
Injector 3 • Set Engine at idling
comes different (be-
Injector 4 speed
comes unstable)

13A FUEL <CFE>
T
AF
R
DOIQC13AR11134
D

FUEL <CFE> 13A
FUEL PUMP RELAY WCH13ASHOOT11209
T
AF
R
D
DOIQC13AR11135
OPERATION
The fuel pump is driven when the engine is cranking and running.

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

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

FUEL <CFE> 13A
T
AF
R
D
DOIQC13AR11136
MISFIRE WCH13ASHOOT11210
OPERATION
Commonly, misfire is due to the incompleteness of burning mixture between air and fuel. This problem
may be either due to the malfunction of ignition coil or spark plug or leakage of air flow to the engine.
Consequently, the compression between air and fuel by piston is not in optimum (2–18° BTDC-engine
idling or 2–45° BTDC-engine at 2500 r/min ). The incompleteness of burning mixture results carbon
monoxide, a pollutant gas which can pollute the environment.

13A FUEL <CFE>
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
P0304 Misfire on cylinder 4 misfire (one of the
ted ning
coils fails).
Catalyst damaging misfire
cylinder 1
cylinder 2
Dynamic Display
cylinder 3
T Engine runs at idle 0 ~ 65535

AF
cylinder 4
potential
R
D

FUEL <CFE> 13A
T
AF
R
D
DOIQC13AR11137

13A FUEL <CFE>
KNOCK SENSOR WCH13ASHOOT11211
T
AF
R
DOIQC13AR11138
OPERATION
The detonation sensor converts cylinder block vibration caused by detonation into a voltage that is
D
proportional to intensity of vibration, and sends it to the engine control unit, which then provides
delay control of the ignition timing based on this signal.

FUEL <CFE> 13A
Check condi-
tion
Knock control system • Engine is run-
Ignition switch: ON
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
T of the crankshaft) is
less than 0.06 V for
200 times in succe-
AF
sion.
Data List Anti Knock Control Status Ignition On OFF / ON
R
D

13A FUEL <CFE>
T
AF
R
DOIQC13AR11139
D

FUEL <CFE> 13A
CRANKSHAFT SENSOR WCH13ASHOOT11212
T
AF
R
DOIQC13AR11140
OPERATION
The crankshaft sensor senses the crank angle (piston position) of each cylinder, converts it into a pulse
D
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

13A FUEL <CFE>
Check condi-
tion
crankshaft sensor failure crankshaft sensor fail-
Engine is run-
P0335 open or short circuit ure open or short
ning
diagnosis CRK_OC circuit
crankshaft signal miss- • Engine is running Engine is run-
crankshaft signal missing
ing Set conditions: ning
crankshaft signal im- crankshaft signal im- • Sensor output Engine is run-
plausible plausible voltage does not ning
crankshaft loss of syn- crankshaft synchroniz- change for 4 Engine is run-
P0336 seconds (no pulse
chronization diagnosis ation lost ning
crankshaft tooth num- wrong crankshaft signal input) Engine is run-
ber error diagnosis tooth number ning
crankshaft tooth period crankshaft tooth peri- Engine is run-
diagnosis od out of range ning
Function PADT-II Display Full name Check condition Standard value
Data List Target Wheel Adapt- Target Wheel Adapt- Idle speed (Engine runs
Performed
ation ation for 5 minutes)
TROUBLESHOOTING PROSEDURE
T
AF
R
D
DOIQC13AR11141

FUEL <CFE> 13A
IGNITION COIL WCH13ASHOOT11213
T
AF
R
D
DOIQC13AR11142
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.

13A FUEL <CFE>
Check condi-
tion
Ignition Coil 1 open cir- Engine is run-
P0351
cuit ning
P0352
cuit ning
Open circuit
P0353
cuit ning
P0354 • Engine speed is ap-
cuit ning
prox. 500-4000
Ignition Coil 1 short cir- r/min . Engine is run-
cuit to ground • Engine is not ning
Ignition Coil 1 short cir- cranking. Engine is run-
cuit to battery Set conditions: ning
Ignition Coil 3 short cir- • The crank angle Engine is run-
P2303 Short circuit to ground sensor detects an
cuit to ground ning
Ignition Coil 3 short cir- abnormal engine Engine is run-
P2304 Short circuit to plus speed caused by
cuit to battery ning
T
misfire (one of the
Ignition Coil 4 short cir- coils fails). Engine is run-
cuit to ground ning
Ignition Coil 4 short cir- Engine is run-
AF
cuit to ground ning
R

Ignition On 0 °C (32 °F) CA IGN OFF
Data List Ignition Timing 9.2 °C (48.56 °F) ~ 11.7 °C
Engine runs at idle
(53.06 °F) CA
D

FUEL <CFE> 13A
T
AF
R
DOIQC13AR11143
CATALYTIC SYSTEM WCH13ASHOOT11214

D
DOIQC13AR11144
OPERATION
Catalytic converter is designed specifically to reduce the pollution air due to the pollutant gases (i. e.
carbon monoxide), resulted from the burning mixture of air and fuel. It removes the gases from the
engine to ensure that the burning mixture of air and fuel are in optimum condition. Basically, the
catalytic converter system consists of primary catalytic converter and secondary catalytic converter.
The primary catalytic converter ensures that all the gases are removed from the engine while the
secondary catalytic converter checks whether the gases is totally removed.

13A FUEL <CFE>
Fault Symptom Descrip-

PADT-II Display Range of Check Check Condition
Codes tion
• Engine speed is
approx.
500-4000 r/min
Catalyst system effi- .
0420 ciency below Catalyst efficiency • Engine stumbles Engine is running
threshold when the cata-
lytic converter
connector is
plugged out.
Catalyst temperat-
Data List Engine runs at idle 50 ~ 950 °C (122 ~ 1742 °F)
ure model
T
AF
R
D
DOIQC13AR11145

FUEL <CFE> 13A
CANNISTER PURGE SOLENOID VALVE WCH13ASHOOT11215
T
AF
R
D
DOIQC13AR11146
OPERATION
The cannister purge solenoid valve is an ON-OFF type of one which controls introduction of purge air
from the cannister into the intake air plenum.
The battery power is supplied to the cannister purge solenoid valve through main relay. When the
cannister purge solenoid valve turns ON the power transistor in the unit, current flows to the coil,
introduction purge air.

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

FUEL <CFE> 13A
T
AF
R
DOIQC13AR11147
D

13A FUEL <CFE>
ENGINE FAN WCH13ASHOOT11216
T
AF
R
D
DOIQC13AR11148
OPERATION
The power transistor inside the engine-ECU turns the fan motor relay on and off.
When the engine control unit turns the power transistor ON, it supplies the power to the radiator
fan relays. This causes the relay to turn ON, and current is supplied from the ignition switch via these
relays to drive the motor which are connected to them.

FUEL <CFE> 13A
Check condi-
tion
Engine is run-
P0480 Fan 1 Open circuit Open circuit Set conditions: ning and A/C
• Engine and A/C switch is On
switch must be ON Engine is run-
Fan 1 Short circuit To
P0691 Short circuit to ground first. ning and A/C
ground
• The fan motor switch is On
should be heard to Engine is run-
Fan 1 Short circuit To operate.
P0692 Short circuit to battery ning and A/C
Battery
switch is On
Actuator Test Fan 1 Ignition ON be heard when purge
valve is driven
T
AF
R
D
DOIQC13AR11149

13A FUEL <CFE>
AIR CONDITIONING FAN WCH13ASHOOT11217
T
AF
R
D
DOINH13AR11022
OPERATION
When an A/C ON signal is input to engine-ECU carries out control of the stepper motor integrated
with throttle body actuator, and also operates the A/C compressor magnetic clutch.
Fault codes PADT Display Full name Check condition

Air Conditioning Fan, Short Cir- Air Conditioning Fan, Short
cuit To Batt Circuit To Battery
Air Conditioning Fan, Short Cir- Air Conditioning Fan, Short
cuit To Ground/Open Circuit To Ground/Open
Air Conditioning Clutch, Short Air Conditioning Clutch, Short
Circuit To Batt Circuit To Battery
Air Conditioning Clutch, Short Air Conditioning Clutch, Short
Circuit To Ground/Open Circuit To Ground/Open

FUEL <CFE> 13A
Function PADT Display Full name Check condition Standard value

Air Conditioning Ignition ON OFF
AC Signal
Signal Idle speed ON
Data List
Air Conditioning Sys- Air Conditioning
Idle speed Performed
tem System
Air conditioning fan Fault codes PADT Display Probable cause
Air Conditioning
P0481 Fan, Short Circuit To • Malfunction of A/C
Batt control system.
Set conditions: Air Conditioning • Malfunction of A/C
• Engine is running at idle speed. P0481 Fan, Short Circuit To switch.
• A/C switch is ON - Blower Relay Ground/Open • Improper connector
operates. Air Conditioning contact, open circuit
• The compressor fan can be P0646 Clutch, Short Circuit or. short-circuit har-
heard once it operates. To Batt ness wire.
Air Conditioning • Malfunction of the
P0647 Clutch, Short Circuit engine-ECU.
To Ground/Open
T
AF
R
D

13A FUEL <CFE>
T
AF
R
D
DOINH13AR11023

FUEL <CFE> 13A
VEHICLE SPEED SIGNAL [ CVT ] WCH13ASHOOT11218
T
AF
R
D
DOIQC13AR11152
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 and ECU by TCU via CAN bus.

13A FUEL <CFE>
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-
T tions:
• Sensor output
voltage does
AF
not change for
4 seconds (no
pulse signal in-
put).
0 km/h (0 mph)
R
Data List Vehicle Speed Ignition ON (Data increases as the

vehicle moves)
D

FUEL <CFE> 13A
T
AF
R
D
DOIQC13AR11153

13A FUEL <CFE>
BRAKE LIGHT SWITCH (Stop lamp switch) WCH13ASHOOT11219
T
AF
R
D
DOIQC13AR11154

FUEL <CFE> 13A
OPERATION
The brake light switch operates when the pedal is pressed. It signals the brake lamp to ON once the
pedal brake is pressed. The power from battery is supplied to the brake light switch and is connected
to the ECU-engine control unit.
Check condi-
tion
Set conditions:
• Pedal brake
pressed-brake light
Engine is run-
P0504 Brake Switch Error plausibility ON.
ning
• Pedal brake re-
leased-brake light
OFF.
T
AF
R
D
DOIQC13AR11155

13A FUEL <CFE>
ENGINE SPEED SIGNAL [ CVT ] WCH13ASHOOT11220
T
AF
R
D
DOIQC13AR11156
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.
TCU received backup signal from ECU by hard disk connection at pin 75 (ECU) in the case of CAN signal
error.

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

Engine run at idle, a/c on ± 850 rpm
D

13A FUEL <CFE>
T
AF
DOIQC13AR11157
R
D

FUEL <CFE> 13A
IMMOBILISER WCH13ASHOOT11221
T
AF
R
D
DOIQC13AR11158
OPERATION
Immobiliser is designed to provide protection from automobile thefts. This system is equipped with
a software to lock the engine control unit. The engine control unit can only operate if the touch key
is placed at the touch key receiver which is integrated with key ring antenna. Once the touch key is
contacted with touch key receiver, and the right code is sent to the ECU which enables the engine to
start.
Check condi-
tion
immobilizer failure
P0513 Immobilizer Locked due to wrong authen- Ignition On
• Check the key ring
tication process
connection with
immobilizer failure engine ECU
Communication with
P0633 due to no communica- Ignition On
Transponder Missing
tion with transponder

13A FUEL <CFE>
T
AF
R
DOIQC13AR11159
D

FUEL <CFE> 13A
POWER SUPPLY WCH13ASHOOT11222
T
AF
R
D
DOIQC13AR11160

13A FUEL <CFE>
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
T
AF
R
D
DOIQC13AR11161

FUEL <CFE> 13A
CRUISE CONTROL WCH13ASHOOT11223
T
AF
R
DOIQC13AR11162
OPERATION
The cruise control function is to set up a constant speed of car set by the users. It enables the car to
D
move at the setting speed without pressing accelerator pedal. There are 4 switches integrated with
cruise control switch, which are main, coast, set and cancel. Each of them has its own function.
Fault Codes PADT-II Display Symptom description Check Condition

Cruise control device dia- Cruise control device
gnosis - resume switch stuck
gnosis - deccelerate gnosis
P0568 Ignition On
gnosis - accelerate gnosis
P0564 Ignition On
gnosis - ON/OFF gnosis
Cruise control device dia- Cruise control device Im-
P0585 Ignition On
gnosis plausible

13A FUEL <CFE>

Cruise control switch, can- Active when cancel lever is
Ignition On
cel activated
Cruise control set delecela- Active when deceleration
Ignition On
tion lever is activated
Cruise control set accelera- Active when acceleration
Data List Ignition On
tion lever is activated
Active when clutch pedal is
Clutch actuated Ignition On
pressed
Vehicle moving > 36 On when cruise control oper-
Cruise control operation
km/h (22.37 mph) ation is activated
T
AF
R
D
DOIQC13AR11163

FUEL <CFE> 13A
ENGINE CONTROL UNIT WCH13ASHOOT11224
DOIQC13AR11164
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 power supply from battery must be checked whether it is properly connected.
Fault codes PADT-II Display
T
Symptom description Range of check
Check condi-
tion
AF
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-
R
ECU Internal Fault - Pro- connecting the

P060C GENERAL Ignition ON
cessor monitoring terminal battery.
D

13A FUEL <CFE>
T
AF
R
DOIQC13AR11165
D

FUEL <CFE> 13A
STARTER CONTROL WCH13ASHOOT11225
T
AF
R
D
DOIQC13AR11166
OPERATION
The starter control is driven when the engine is cranking and while the engine is running.

13A FUEL <CFE>
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
T
AF
R
D
DOIQC13AR11167

FUEL <CFE> 13A
SENSOR SUPPLY WCH13ASHOOT11226
T
AF
R
D
DOIQC13AR11168
OPERATION
Engine ECU check to throttle position sensor, pedal voltage sensor, TMAP sensor and Camshaft sensor
power voltage for abnormal.

13A FUEL <CFE>
Check condi-
tion
• Throttle position
sensor 1 power voltage
Sensor reference voltage less than 4.4 V
P0642
‘A’ circuit LOW • Pedal voltage sensor
1 power voltage less
than4.4 V
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
P0653
T
voltage more than
5.59 V
AF
‘B’ circuit HIGH • Camshaft sensor
power voltage more
than5.59 V
R
D
DOIQC13AR11169

FUEL <CFE> 13A
COMPRESSER WCH13ASHOOT11227
T
AF
R
D
DOIQC13AR11170
OPERATION

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

OFF
Data List Air cond request signal Ignition ON
ON
T
AF
R
D

FUEL <CFE> 13A
T
AF
R
DOIQC13AR11171
D

13A FUEL <CFE>
MAIN RELAY WCH13ASHOOT11228
T
AF
R
D
DOIQC13AR11172

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

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

13A FUEL <CFE>
T
AF
R
D
DOIQC13AR11173

FUEL <CFE> 13A
TRANSMISSION CONTROL UNIT (CVT) WCH13ASHOOT11229
DOIQC13AR11174
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.
T
Symptom descrip-
AF
tion
One of the follow-
ing causes may be
suspected:
• No power
supply to
R
CVT.
• Defective of
Transmission control unit Transmission limp transmission
limp home diagnosis home unit -CVT.
D
• CAN bus is off

• CAN ECU
communica-
tion failed
• CAN engine
torque signal
error
Dynamic Display Gear Lever Position Ignition ON D / P/N

13A FUEL <CFE>
T
AF
R
DOIQC13AR11175
D

FUEL <CFE> 13A
P/N SWITCH WCH13ASHOOT11230
T
AF
R
DOIQC13AR11176
OPERATION
1. For security, the shift lever position must be in either P or N position in order for the engine can
D
be started.
2. CVT - TCU sends the shift lever position to engine ECU via CAN . A back-up signal is send via
hardwire (pin no 92) from CVT-TCU to engine ECU
3. Engine ECU to set an error when it detects differences between CAN signal and the hardwire
signal.
Check condi-
tion
• Ignition switch ON
position
P0850 P/N switch Plausibility Plausible Value Ignition ON
• CAN voltage measure-
ment 0~3 V
Dynamic Display Gear position Ignition ON D, P/N

13A FUEL <CFE>
T
AF
R
DOIQC13AR11177
D

FUEL <CFE> 13A
PEDAL/BRAKE SWITCH WCH13ASHOOT11231
T
AF
R
D
DOIQC13AR11178

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

FUEL <CFE> 13A
T
AF
R
D
DOIQC13AR11179

13A FUEL <CFE>
CAN COMUNICATION WCH13ASHOOT11232
T
AF
R
D
DOIQC13AR11180
OPERATION
Engine control unit monitors and interacts with the Transmission Control Unit to ABS and meter
combination ensure that the transmission unit operates in a good condition. By plugging the PADT-
II to the ECU connector, the errors in the control unit area can be detected easily.

FUEL <CFE> 13A
Fault
PADT-II Display Symptom description Range check Check condition
codes
CAN Diagnosis -
U0073 CAN bus off Engine is running
Buss Off
Error in the respect-
CAN Diagnosis - Lost
ive Control Unit (CU)
U0100 Communication Engine is running
communicating on
with ECU
the CAN-HS bus
CAN Diagnosis - Lost • Check the wiring
U0101 Communication harness between Engine is running
communicating on
with TCU ECU connector
the CAN-HS bus
and TCU connect-
Error in the respect- or.
communicating on
with ABS/ESP
the CAN-HS bus
communicating on
T
with meter cluster
the CAN-HS bus
AF
R
D
DOIQC13AR11181

13A FUEL <CFE>
VVT SOLENOID WCH13ASHOOT11233
T
AF
R
D
DOIQC13AR11182
OPERATION
The engine ECU calculates the intake timing and actuator the oil control valve to modulate oil pressure
on intake camshaft.The engine ECU will set a fault when it detects a malfunction at the oil control
valve.

Camshaft Control Open Cir-
P0660 Open Circuit
cuit
P0661 Short Circuit to Ground Engine runs at idle
cuit to Ground
cuit to Battery
Data List VVT Control Active Engine runs at idle Not active / active

FUEL <CFE> 13A
T
AF
R
D
DOIQC13AR11183

13A FUEL <CFE>
BOOST DUMP VALVE (ELECTRONIC CONTROL RELIEF VALVE) WCH13ASHOOT11234
T
AF
R
DOIQC13AR11184
OPERATION
Boost dump valve is a pressure release system to prevent the compresser surge when the throttle is
D
fitted/closed. The engine ECU control the boost dump valve to release the pressurized an back to the

Boost Bypass Valve Stuck
P1427 Plausibility stuck close Engine is running
Close
Boost Bypass Valve Stuck
P1428 Plausibility stuch open Engine is running
Open
Canister purge solenoid
P1430 Open Circuit Ignition On
valve Open Circuit
P1431 valve short Circuit to Short Circuit to Ground Ignition On
ground
P1432 valve short Circuit to bat- Short Circuit to Plus Ignition On
tery
Boost Recirculation Valve
Data List Engine runs at idle Off/ on
Open

FUEL <CFE> 13A
T
AF
R
D
DOIQC13AR11185

13A FUEL <CFE>
RECIRCULATION PUMP WCH13ASHOOT11235
T
AF
R
D
DOIQC13AR11186
OPERATION
The power transistor inside the engine ECU turns the recirculation pump relay on and off when the
engine is turn off, engine ECU turns the power transistor ON, and the recirculation pump relay supplies
power to the recirculation pump.
Symptom Descrip-
Fault codes PADT-II Display Check condition
tion
P2600 Open circuit
trol Open circuit
Coolant Water Pump Con- Short circuit to
P2602 Engine ON
trol short circuit to ground ground
trol short circuit to battery

FUEL <CFE> 13A

Data List Recirculation Pump Active Engine ON Off/ on
T
AF
R
D
DOIQC13AR11187

13A FUEL <CFE>
MAP 2 (MANIFOLD AIR PRESSURE) WCH13ASHOOT11236
T
AF
R
DOIQC13AR11188

The vacuum sensor converts the air intake plenum pressure to a voltage value .and inputs it to the
D
engine control unit. The engine control unit uses this signal and the engine rpm to calculate the basic
fuel injection timing.
Boost pressure to 5V of power is supplied to the vacuum sensor from the engine control unit, and the
sensor circuit earth is located in the engine control unit. The vacuum sensor output voltage is propor-
tioned to the air intake plenum pressure and sent to the engine control unit.
When the pressure is more than 1.1 bar, the engine control will send signal to boost dump to release
the presure.

FUEL <CFE> 13A
Check condi-
Fault codes PADT-II Display Range of Check
tion
Basic Air Pressure Adapt- Adaptation reached • Ignition switch: ON Engine is run-
P1252
ation Low Threshold low threshold • The output voltage ning
of the boost sensor
is 4.5 V or more
for 4 seconds. (This
corresponds to the
absolute manifold
pressure of 100
kPa (14.23 psi,
30.19 in.Hg) or
more).
of the throttle
sensor is 1.25 V or
Basic Air Pressure Adapt- Adaptation reached more. Engine is run-
P1251
ation High Threshold high threshold • The vehicle is sta- ning
tionary
Set conditions:

of the boost sensor
AF
4 seconds. (This
correspond to the
absolute manifold
pressure of 4.9
kPa (0.7 psi, 1.48
in.Hg) or less).
R

Manifold Pressure Idle speed 490 hPa
Manifold Pressure Volt Ignition On 1.2 mv
D
Manifold Pressure Volt Idle speed Performed

Data List
Ambient Pres-sure Engine runs at idle 500 ~ 1000 hPa
Pressure Up-stream
Engine runs at idle 0 ~ 1800 hPa
Throttle

13A FUEL <CFE>
T
AF
R
DOIQC13AR11189
D

FUEL <CFE> 13A
WASTE GATE WCH13ASHOOT11237
T
AF
R
DOIQC13AR11190
OPERATION
Waste gate regulates the maximum boost pressure in turbocharger system. It protects the engine and
D
the turbocharger by diverting the exhaust gas away from the turbine wheel.
Engine ECU control the boost pressure (wastegate actuator) by regulating the PWM valve.

Turbocharger/Supercharger Charge Air Pressure too
P0234
Overboost Condition high
Wastegate Actuator Open
P0243 Open circuit
Circuit
Wastegate Actuator Circuit
to ground
Ignition On
Wastegate Actuator Circuit
to battery
Waste gate diagnosis for
high speed
Waste gate diagnosis for
low speed

13A FUEL <CFE>

Boost Control Adaptation
-2717.04 ~ 2716.95 hPa
1
Data list Engine Runs At Idle
Boost Control Adaptation
± 1.999 bar
2
T
AF
R
D
DOIQC13AR11191

FUEL <CFE> 13A
TURBO CHARGER WCH13ASHOOT11238
DOIQC13AR11192
OPERATION
The engine ECU check whether the intake air for the engine is sufficient by monitoring the amount
at intake air.
Symptom Descrip-
T
tion
Turbocharger/Super-
Charge Air Pressure
P0234 charger Overboost
AF
too high
Condition
Diagnosis Turbochar-
Basic Charge air Engine Speed is
ger/Supercharger Un-
Pressure too Low more than 3000
derboost Condition Ignition on
P0299 rpm and less
Turbocharger/Super- than 5000 rpm
Charge Air Pressure
charger Underboost
R
too Low
Condition
Turbocharger Over- Turbo charger
P2578
speed speed exceed limit
D

13A FUEL <CFE>
/ 134 TROUBLE SYMPTOM
T
AF
R
DOIQC13AR11193
TROUBLE SYMPTOM WCH13ASHOOT11239

D
INSPECTION CHART FOR TROUBLE SYMPTOMS

Inspection
Trouble symptom procedure Reference page
No.
Communication with all
1 13A/137
systems is not possible
Communication with PADT-II is
impossible Communication with en-
gine-ECU only is not pos- 2 13A/138
sible
The engine warning lamp
does not illuminate right
after the ignition switch 3 13A/139
Engine warning lamp and related is turned to the ON posi-
parts tion
remains illuminating and 4 13A/140
never goes out

FUEL <CFE> 13A
TROUBLE SYMPTOM / 135
Inspection
No.
No initial combustion
5 13A/141
(starting impossible)
Initial combustion but no
Starting complete combustion 6 13A/142
Takes too long time to
7 13A/143
start (improper starting)
Unstable idling (Rough
8 13A/144
Idling, hunting )
Idling speed is high (Im-
Idling stability (Improper idling) 9 13A/145
proper idling speed)
Idling speed is low (Im-
10 13A/146
When the engine is cold,
11 13A/147
it stalls at idling (Die out)
Idling stability (Engine stalls)

T
When the engine be-
comes hot, it stalls at id-
ling (Die out)
12 13A/148
AF
The engine stalls when
13 13A/149
starting the car (Pass out)
14 13A/150
decelerating
Hesitation, sag or stumble 15 13A/151
The feeling of impact or
R
vibration when accelerat- 16 13A/152

ing
Driving
D
vibration when decelerat- 17 13A/153

ing
Poor acceleration 18 13A/154
Surge 19 13A/155
Knocking 20 13A/156
Dieseling 21 13A/157
Too high CO and HC concentration when idling 22 13A/158
Low alternator output voltage (approx. 12.3 V ) 23 13A/159
Power supply system and ignition switch-IG system 24 13A/159
Fuel pump system 25 13A/160
Ignition switch-ST system <M/T> 26 13A/161
Ignition switch-ST and inhibitor switch system <A/T> 27 13A/162
A/C switch and A/C relay system 28 13A/163
Fan motor relay system (Radiator fan, A/C condenser fan) 29 13A/164
Tank purge valve system 30 13A/165
PADT-II: Inspection of no initial combustion 31 13A/166
Ignition system: Inspection of no initial combustion 32 13A/167

13A FUEL <CFE>
Inspection
No.
PADT-II: Check if incomplete combustion occurs 33 13A/168
Check if hunting occurs 34 13A/169
PADT-II: Check if idling speed is unstable 35 13A/170
PADT-II: Engine stalling inspection when the engine is
36 13A/171
warmed up and idling
PADT-II: Check if hesitation, sag, stumble or poor accelera-
37 13A/172
tion occurs
PADT-II: Check if surge occurs 38 13A/173
Check the engine-ECU power supply and earth circuit 39 13A/174
Check fuel pump circuit 40 13A/175
Check fuel pump drive control circuit 41 13A/176
Check throttle body actuator (TBA) output circuit 42 13A/177
Check injector control circuit 43 13A/178
Check ignition coil and power transistor unit circuit 44 13A/179
PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)
T WCH13ASHOOT11240
AF
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.
R
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
D
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.

FUEL <CFE> 13A
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS / 137
Items Symptom
“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.
T
The condition in which the engine continues to run
Stopping Run on (“Dieseling”) after the ignition switch is turned to OFF. Also called
“Dieseling”.
AF
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS WCH13ASHOOT11241
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
R
Probable cause
all systems is not possible )
• Malfunction of the connect-
The cause is probably a defect in the power supply system (including or.
D
earth) for the diagnosis line. • Malfunction of the harness

wire.

13A FUEL <CFE>
/ 138 INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
T
AF
DOIQC13AR11194
INSPECTION PROCEDURE 2 WCH13ASHOOT11242
PADT-II Communication with engine-ECU is impossible

R
PADT-II — Communication with engine-ECU is

Probable cause
impossible
D
One of the following causes may be suspected:

• No power supply to engine-ECU. • Malfunction of engine-ECU power supply circuit.
• Defective earth circuit of engine-ECU. • Malfunction of engine-ECU.
• Defective engine-ECU. • Open circuit between engine-ECU and diagnosis
• Improper communication line between en- connector.
gine-ECU and PADT-II.

FUEL <CFE> 13A
T
AF
DOIQC13AR11195
R
The engine warning lamp does not illuminate right after the ignition switch is turned to the ON
position
D
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.

13A FUEL <CFE>
T
AF
DOIQC13AR11196
R
The engine warning lamp remains illuminating and never goes out.
D
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.

FUEL <CFE> 13A
T
AF
R
D
DOIQC13AR11197
No initial combustion (starting impossible)

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

13A FUEL <CFE>
T
AF
DOIQC13AR11198
R
Initial combustion but no complete combustion (starting impossible)

D
Initial combustion but no complete combustion (starting Probable cause

impossible)
• Malfunction of the ignition sys-
tem.
• Malfunction of the injectors sys-
In such cases as the above, the cause is probably that the spark tem.
plugs are generating sparks but the sparks are weak, or the • Malfunction of the throttle body
initial mixture for starting is not appropriate. actuator system.
• Foreign materials in fuel.
• Poor compression.

FUEL <CFE> 13A
T
AF
DOIQC13AR11199
R
Takes too long time to start (Incorrect Starting)

D
Takes too long time to start (Incorrect Starting) Probable cause

that the spark is weak and ignition is difficult, • Malfunction of the injectors system.
the initial mixture for starting is not appropriate, • Inappropriate gasoline use.
or sufficient compression pressure is not being • Poor compression.
obtained.

13A FUEL <CFE>
T
AF
DOIQC13AR11200
R
Unstable idling (Rough idling, hunting)

D
Unstable idling (Rough idling, hunting) Probable cause

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

FUEL <CFE> 13A
T
AF
DOIQC13AR11201
R
Idling speed is high (Improper idling speed)

D
Idling speed is high (Improper idling speed) Probable causes

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

13A FUEL <CFE>
T
AF
DOIQC13AR11202
R
Idling speed is low (Improper idling speed )

D
Idling speed is low (Improper idling speed) Probable cause

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

FUEL <CFE> 13A
T
AF
DOIQC13AR11203
R
When the engine is cold, it stalls at idling (Die out)

D
When the engine is cold, it stalls at idling (Die

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

13A FUEL <CFE>
T
AF
R
D
DOIQC13AR11204
When the engine is hot, it stalls at idling (Die out)

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

FUEL <CFE> 13A
T
AF
R
D
DOIQC13AR11205
The engine stalls when starting the car (Pass out)

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

13A FUEL <CFE>
T
AF
DOIQC13AR11206
R
The engine stalls when decelerating

D
The engine stalls when decelerating Probable cause

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

FUEL <CFE> 13A
T
AF
DOIQC13AR11207
R
Hesitation, sag or stumble

D
Hesitation, sag or stumble Probable cause

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

13A FUEL <CFE>
T
AF
DOIQC13AR11208
R
The feeling of impact or vibration when accelerating

D
The feeling of impact or vibration when

Probable cause
accelerating
that there is an ignition leak accompanying the • Malfunction of the ignition system.
increase in the spark plug demand during accel-
eration.

FUEL <CFE> 13A
T
AF
DOIQC13AR11209
The feeling of impact of vibration when decelerating

R
The feeling of impact of vibration when

Probable cause
decelerating
D
Malfunction of the throttle body actuator sys- • Malfunction of the throttle body actuator system.
tem is suspected.

13A FUEL <CFE>
T
AF
DOIQC13AR11210
R
Poor acceleration
D
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.

FUEL <CFE> 13A
T
AF
DOIQC13AR11211
R
Surge
D
Surge Probable cause

Defective ignition system, abnormal air-fuel ratio, etc. • Malfunction of air-fuel ratio control sys-
are suspected. tem.
• Injectors do not work.

13A FUEL <CFE>
T
AF
DOIQC13AR11212
R
Knocking
D
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

FUEL <CFE> 13A
T
AF
DOIQC13AR11213
R
Dieseling
D
Dieseling Probable cause

Fuel leakage from injectors is suspected. • Fuel leakage from injectors.
DOIQC13AR11214

13A FUEL <CFE>
Too high CO and HC concentration when idling

Too high CO and HC concentration when idling Probable cause
• Malfunction of the air-fuel control system.
Abnormal air-fuel ratio is suspected. • Front and rear oxygen sensor do not work.
• Deteriorated catalyst.
T
AF
R
D
DOIQC13AR11215

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

Low Alternator Output Voltage (Approx. 12.3 V ) Probable cause
• Malfunction of charging system (Refer to
GROUP 16-ENGINE ELECTRICAL FOR
The alternator may be defective, or malfunction, which CHARGING SYSTEM CHECK.).
are listed in the right column, may be suspected. • Short circuit in harness between alternat-
or G terminal and engine-ECU.
T
AF
R
D
DOIQC13AR11216
Power supply system and ignition switch-IG system

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

13A FUEL <CFE>
T
AF
DOIQC13AR11217

R
Fuel pump system

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

FUEL <CFE> 13A
T
AF
DOIQC13AR11218
R
Ignition switch-ST system [M/T]

D
Ignition switch-ST system [M/T] Probable cause

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

13A FUEL <CFE>
T
AF
DOIQC13AR11218
R
Ignition switch-ST and inhibitor switch system [CVT]

D
Ignition switch-ST and inhibitor switch system [CVT] Probable cause

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

FUEL <CFE> 13A
T
AF
DOIQC13AR11220
R
A/C switch and A/C relay system

D
A/C switch and A/C relay system Probable cause

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

13A FUEL <CFE>
T
AF
DOIQC13AR11221
R
Fan motor relay system (Radiator fan)

D
Fan motor relay system (Radiator fan) Probable cause

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

FUEL <CFE> 13A
T
AF
DOIQC13AR11222
R
Tank purge valve system

D
Tank purge valve system Probable cause

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

13A FUEL <CFE>
T
AF
DOIQC13AR11223
R
PADT-II: Inspection of no initial combustion

D
Inspection of no initial combustion Probable cause

• Malfunction of camshaft sensor
In such cases above, the the cause is probably malfunc- • Malfunction of crank angle sensor
tion of sensors and actuators as per next table • Malfunction of fuel pump system
• Malfunction of coolant temperature sensor

FUEL <CFE> 13A
T
AF
DOIQC13AR11224
R
Ignition system: Inspection of no initial combustion

D

The cumbustion is initiate by the ignition system, where signal • Malfunction of ignition system
is sent to engine ECU and the ECU turns the injectors and ignition • Malfunction of crank angle sensor
coil . • Malfunction of engine ECU

13A FUEL <CFE>
T
AF
DOIQC13AR11225
PADT-II: Check if incomplete combustion occurs

R
In complete combustion occurs Probable cause

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

FUEL <CFE> 13A
T
AF
DOIQC13AR11226
R
Check if hunting occurs

D
Hunting occurs Probable cause

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

13A FUEL <CFE>
T
AF
DOIQC13AR11227
PADT-II: Check if idling speed is unstable

R
Idling speed is unstable Probable cause

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

FUEL <CFE> 13A
T
AF
R
D
DOIQC13AR11228
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 air system

13A FUEL <CFE>
T
AF
R
D
DOIQC13AR11229
PADT-II: Check if hesitation, sug, stumble or poor acceleration occurs

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

FUEL <CFE> 13A
T
AF
R
D
DOIQC13AR11230
PADT-II: Check if surge occurs

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

13A FUEL <CFE>
T
AF
R
D
DOIQC13AR11231
Check the engine-ECU power supply and earth circuit

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

FUEL <CFE> 13A
T
AF
DOIQC13AR11232
R
Check fuel pump motor circuit

D
Check fuel pump motor circuit Probable cause

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

13A FUEL <CFE>
T
AF
DOIQC13AR11233
R
Check the fuel pump relay drive circuit

D
Check the fuel pump relay drive circuit Probable cause

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

FUEL <CFE> 13A
T
AF
DOIQC13AR11234
R
Check throttle body actuator (TBA) output circuit

D
Check throttle body actuator (TBA) output

Probable cause
circuit
In such cases, the cause is probably as listed • Throttle body actuator harness open circuit/ short cir-
in the next column cuit

13A FUEL <CFE>
T
AF
DOIQC13AR11235
R
Check injector control circuit

D
Check injector control circuit Probable cause

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

FUEL <CFE> 13A
T
AF
DOIQC13AR11236
R
Check ignition coil and power transistor unit circuit

D
Check ignition coil circuit Probable cause

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

13A FUEL <CFE>
/ 180 DATA LIST
T
AF
DOIQC13AR11237
R
DATA LIST WCH13ASHOOT11198
DATA LIST REFERENCE TABLE

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

FUEL <CFE> 13A
DATA LIST / 181
In a new vehicle [driven approximately 500 km (310.68 mile) or less], the step of the stepper
motor is sometimes 30 steps greater than the standard value.
CURR PADT– II DIS- CHECK CON- STANDARD

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

13A FUEL <CFE>
/ 182 DATA LIST

USAGE UNIT REMARKS
Ign on 0 ~ 900 mv
Front oxygen
15 IAFM+/CFE Engine runs mV Voltage oxygen sensor
sensor voltage 180 ~ 400
at idle
Ign on 0 ~ 900 mv
Rear oxygen
16 IAFM+/CFE Engine runs mV Voltage oxygen sensor
sensor voltage 180 ~ 401
at idle
Oxygen long Engine runs
17 IAFM+/CFE ± 30 % Fuel adaptation
term adaptation at idle
Oxygen long
term adaptation Engine runs
multiplicative at idle
value
Oxygen long
term adaptation Engine runs
fuel mass flow at idle
offset
20
Catalyst temper-
ature model
IAFM+/CFE
Engine runs
at idle
T
50 ~ 950 °C
(122 ~ 1742
°F)
°C Catalyst temperature
AF
Catalyst dam-
Engine runs Misfire detection counter - cylin-
21 aging misfire IAFM+/CFE 0 ~ 65535 —
at idle der 1
cylinder 1
Catalyst dam-
at idle der 2
cylinder 2
R
Catalyst dam-
at idle der 3
cylinder 3
D
Catalyst dam-
at idle der 4
cylinder 4
Catalyst dam-
Engine runs
25 aging misfire IAFM+/CFE 0 ~ 65535 — —
at idle
potential
Idle torque loss ±3 kgm (30
Engine runs
26 adaptation IAFM+/CFE Nm, 21.7 Nm Torque losst adaptation
at idle
value ft.lbs)
Accelerator ped-
27 IAFM+/CFE Ign on 0.00 % Varies when aps pressed
al position
Distance since
28 IAFM+/CFE Ign on 0 km Check fault code if value > 0km
mil on
Engine runs
29 Mass air flow CFE 0 ~ 800 mg_sttk Mass air flow
at idle
Ambient pres- Engine runs
30 CFE 500 ~ 1000 hPA Ambient pressure
sure at idle
Pressure up- Engine runs
31 CFE 0 ~ 1800 hPa Boost pressure
stream throttle at idle

FUEL <CFE> 13A
DATA LIST / 183

USAGE UNIT REMARKS
Estimated en-
Engine runs
32 gine torque at CFE 30 ~ 210 Nm Engine torque
at idle
clutch
Boost control Engine runs
33 CFE 0 ~ 99.99 % Wastegate opening
valve duty cycle at idle
Intake cam posi- Engine runs
34 CFE -50 ~ 50 °CRK VVT opening
tion at idle
Engine cooling Engine runs
35 CFE 0 ,1, 3 — Fan activation
fan state at idle
Idle torque loss
Engine runs
36 adaptation for CFE ± 30.0 Nm Torque losst adaptation
at idle
air con
Idle torque loss
Engine runs
37 adaptation for CFE ± 30.0 Nm Torque losst adaptation
at idle
transmission
Ron ignition ad- Engine runs
38 CFE 0 ~ 47.990 °CRK Flex fuel adaptation
T
aptation at idle
Ron ignition ad- Engine runs
39 CFE 0 ~ 0.99 — Flex fuel adaptation
aptation factor at idle
AF
Additive
Engine runs
40 throttle area ad- CFE ± 29.29 cm2 Throttle air flow adaptation
at idle
aptation
Multiplicative
Engine runs
41 throttle area ad- CFE ± 50.0 % Throttle air flow adaptation
at idle
aptation
R
Boost control Engine runs -2717.04 ~

42 CFE hPa Boost adaptation
adaptation 1 at idle 2716.95
Boost control Engine runs
43 CFE ± 1.999 bar Boost adaptation
D
adaptation 2 at idle
Engine runs Not active / Idle state status; active when idle
44 Idle state IAFM+/CFE —
at idle active switch is on
Engine runs Not active / Load status; active when acceler-
45 Full load request IAFM+/CFE —
at idle active ator pedal at full throttle
Gear position; d hwen gear posi-
46 Gear position IAFM+/CFE Ign on D, p/n — tion set to drive, p/n when gear
shift to parking/neutral
Air cond request Engine runs Air conditioner status; on when
47 IAFM+/CFE Off / on —
signal at idle air cond switch to on
Camshaft con- Engine runs
48 IAFM+/CFE Off / on — VVT controller status
trol at idle
Intake manifold Engine runs
49 IAFM+/CFE Off / on — VIM controller status
control at idle
Anti knock con- Engine runs
50 IAFM+/CFE Off / on — Knock control status
trol status at idle
Fuel cut off Engine runs
51 IAFM+/CFE Off / on — Fuel cut off condition
(SAS) at idle

13A FUEL <CFE>
/ 184 ACTUATOR TEST

USAGE UNIT REMARKS
Throttle body Throttle body adaptation status;
Engine runs In progress /
52 adaptation IAFM+/CFE — done when tba adaptation is
at idle done
(TBA) completed
Cruise control cancel switch
Cruise control - Engine runs Not active /
53 IAFM+/CFE — status; active when cruise cancel
cancel switch at idle active
switch is cancelled
Cruise control switch status; act-
Cruise control Engine runs Not active /
54 IAFM+/CFE — ive when cruise control switch is
set deceleration at idle active
set to decelerate
Cruise control switch status; act-
Cruise control Engine runs Not active /
55 IAFM+/CFE — ive when cruise control switch is
set acceleration at idle active
set to accelerate
Clutch actuated Engine runs Not active /
56 IAFM+/CFE — —
(m/t) at idle active
Cruise control operation status;
Cruise control Engine runs
57 IAFM+/CFE Off / on — on when auto cruise in operating
operation at idle
mode
58
Target wheel
adaptation
IAFM+/CFE
Engine runs In progress /
at idle done
T — —
AF
Recirculation
59 CFE Ign on Off / on — Turbocharger cooling system
pump active
Air cond clutch Engine runs
60 CFE Off / on — Air cond engagement
engaged at idle
MIL indication
61 CFE Ign on Off / on — —
on
R
VVTcontrol act- Engine runs Not active /

62 CFE — VVT activation status
ive at idle active
Trailing throttle Not active /
63 CFE Ign on — Engine state
D
state active
Engine runs Not active/
64 Part load state CFE — Engine state
at idle active
Boost recircula- Engine runs
65 CFE Off/ on — Boost bypass valve
tion valve open at idle
ACTUATOR TEST WCH13ASHOOT11285
ACTUATOR TEST REFERENCE TABLE

Item Inspection Inspection Normal Inspection proced-
Drive contents
No. item contents condition ure No.
Front Oxy- Actuate the Front Oxy-
Check status
1 gen Sensor Lambda probe Idling speed gen control- 13A/40
on PADT-II
Heater heater 1 to ON ler = ON
Rear Oxygen Actuate the Rear Oxy-
Check status
2 Sensor Heat- Lambda probe Idling speed gen control- 13A/43
on PADT-II
er heater 2 to ON ler = ON

FUEL <CFE> 13A
ACTUATOR TEST / 185
Item Inspection Inspection Normal Inspection proced-

Drive contents
No. item contents condition ure No.
Pinch the re-
• Ignition turn hose with
switch: ON fingers to feel
• Fuel pump Pulse is felt
the pulse of
Fuel pump oper- Forced driv- the being recir-
3 Fuel pump ates and fuel is ing Inspect culated. 13A/65
recirculated. according to
both the Listen for the
Sound of
above condi- sound of fuel
operation is
tions pump opera-
heard
tion.
Cut fuel to No. 1
4 Injector 1
injector Idling condi-
Injector 2 Cut fuel to No. 2 • Warmed up
5 tion be-
injector the Engine for Check cylin-
comes dif-
few minutes ders which af- 13A/62
Injector 3 Cut fuel to No. 3 ferent (be-
6 • Set Engine at fect idling
injector comes un-
idling speed
Injector 4 Cut fuel to No. 4 stable)
7
injector
T Sound of
AF
operation
Listen for fan
Drive the fan Ignition switch: can be
motor opera-
motor (radiator) ON heard when
Engine Fan tion sound
8 purge valve 13A/82
(Fan 1) is driven
Drive the fan Ignition switch: Listen for fan
Fan motor
motor (air condi- ON motor opera-
R
run
tioner) A/C Switch: ON tion sound
Throttle Po-
sition Sig-
D
Check status nal = X %

Throttle valve • Warmed up on PADT-II (X value in-
actuate to the Engine for crease from
Throttle
10 1. 0% few minutes 13A/46
valve 0~100%)
2. 50% • Set Engine at
3. 100% idling speed RPM goes
Listen for en- higher from
gine sound idle speed
setting
Purge Duty
Cycle = X %
Check status
(X value in-
on PADT-II
crease from
0~100%)
Purge valve
Ignition switch: Sound of
11 Purge valve turns from OFF 13A/79
ON operation
to ON Listen for
can be
purge valve
heard when
operation
solenoid
sound
valve is
driven

13A FUEL <CFE>
/ 186 CHECK AT THE ENGINE-ECU
CHECK AT THE ENGINE-ECU WCH13ASHOOT11286
DOIMC13AR11032
TERMINAL VOLTAGE CHECK CHART

1. Connect a needle-nosed wire probe (test harness: MB991223 or paper clip) to a voltmeter probe.
2. Insert the neddle-nosed wire probe into each of the engine-ECU connector terminals from the
side, and measure the voltage while referring to the check chart.
NOTE
T
(1) Make the voltage measurement with the engine-ECU connected.
(2) You may find it convenient to pull out the engine-ECU to make it easier to reach connector ter-
AF
minals.
(3) The checks can be carried out off the order given in the chart.
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!
R
Symbol Description
A ECU harness
3. If voltmeter shows any division from standard value, check the corresponding sensor, actuator
D
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.
DOIQC13AR11114
ENGINE-ECU CONNECTOR TERMINAL ARRANGEMENT

CFE/IAFM+

FUEL <CFE> 13A
CHECK AT THE ENGINE-ECU / 187
ECU PIN NUMBER Check condition Normal

Check item
(Part side) (Engine condition) condition
23 Battery Voltage
Always
78 ± 12 V
Power Supply
Battery Voltage
17 Ignition switch: ON
± 12 V
31
Power Ground Ignition switch: OFF ±0V
47
62 Fuel pump relay
Condenser fan mo-
79
tor relay
Radiator fan motor
6 Battery Voltage
relay Ignition switch: ON
± 12 V
74 A/C relay
46 Starter relay
Main relay (Power
63
supply)
90
91
77
Injector – 1
Injector – 2
Injector – 3
T
While engine is idling after having
warmed up, suddenly depress the accel-
From 11-14 V ,
momentarily
AF
erator pedal. drops slightly
92 Injector – 4
Tank Purge Valve Running at 90 °C (194 °F)— 105 °C (221
61 0V—3V
°F)
• Engine: Warm, idle (radiator fan:
OFF)
Alternator G termin- 0.4-0.8 V to 0.8-
23 • Headlamp: OFF→ON
R
al 1.2 V
• Rear defogger switch switch:
OFF→ON
9-13 V (After sev-
Engine warning Ignition switch:
D
5 eral seconds have

lamp OFF→ON
elapsed)
Turn the A/C switch
0-3 V
OFF
43 A/C switch Engine: Idle speed Turn the A/C switch
Battery Voltage
OFF (A/C com-
12 V
pressor is opening)
65 Ignition switch-ST Engine: Cranking 8 V or more
Front oxygen sensor
95 Ignition switch: ON 0-3 V
heater
70 5V
Front oxygen sensor Ignition switch ON
56 410 mv ± 41 mv

13A FUEL <CFE>

Check item
When intake air
temperature is at
3.0 V ± 0.6 V
room temperature
Intake air temperat- 27 °C (80.6 °F)
ure sensor (Com- When intake air
bined map & mat temperature is 40 1.5 - 2.1 V
sensor) °C (104 °F)
When intake air
temperature is 80 0.4 -1.0 V
°C (176 °F)
37 Vacuum sensor ±5V
68 (Combined Map & Ignition switch: ON 4 V ± 0.21 V
54 Mat Sensor) ±0V
84 Ignition switch: ON ±5V
When intake air
temperature is at
3.0 V ± 0.6 V
Engine coolant tem-

perature sensor
T room temperature
27 °C (80.6 °F)
When engine
AF
coolant temperat- 0.3-1.9 V
ure is 40 °C (104 °F)
When engine
ure is 80 °C (176 °F)
39 — ±5V
R
Throttle position Ignition switch: ON

72 — ±0V
Throttle valve
Throttle position 0.5 V ± 0.5 V
71 closed
sensor 1
D
Ignition switch: ON Throttle valve open 4.65 V ± 0.5 V

(move the throttle
valve manually) Throttle valve
87 closed
sensor 2
Throttle valve open 0.35 V ± 0.5 V
60 Engine: Cranking 0.4-3.0 V
Camshaft sensor
73 Engine: Idle speed 0.5-2.0 V
Crankshaft sensor

FUEL <CFE> 13A

Check item
Approximately 5
27
Pedal at all condi- V
Accelerator Pedal tion Approximately 0
12
Sensor 1 V
Pedal release 4.5 V ± 0.5 V
19
Pedal fully pressed 0.55 V ± 0.5 V
Ignition switch: ON
Approximately
11
Pedal at all condi- 2.5 V
20
Sensor 2 V
67
Push the main Approximately 12
24
switch V
Push the ACC set/ Approximately 12
22
Cruise Control Ignition switch Z: RESUME switch V
28
Switch ON
T Push the COAST/

SET switch
Approximately 12
V
AF
Push the cencel Approximately 0
81
switch V
66
Key Ring Antenna Ignition switch: ON 1.5-4.0 V
3
Approximately 0
50
V
R
Knock Sensor Ignition switch: ON

Approximately
34
2.5 mv ± 0.5 mv
48 Ignition Coil – 1
D
80 Ignition Coil – 2 Approximately

Ignition switch: ON
96 Ignition Coil – 3 0.38 V± 0.02 V
Brake pedal press ±0V
82 At all condition Brake pedal release Battery Voltage
± 12 V
Brake Light Switch
Brake pedal press Approximately
30 Ignition switch: ON 2.5 V ± 0.3 V
Brake pedal release 11~14 V
Approximately
1
1.908 V ± 0.2 V
Can Interface Ignition switch: ON
Approximately
9
3.136 V ± 0.2 V
Set selector level to
0V
P or N
42 Start lock Ignition switch: ON
Set selector lever to
12 V
other than P or N

13A FUEL <CFE>

Check item
Engine running Engine at 900 rpm 30 Hz
(Using a digital
75 Engine speed signal
multimeter, switch Engine at 3000 rpm 100 Hz
to frequency mode)
CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS WCH13ASHOOT11287
1. Turn the igniton switch to OFF.

2. Disconnect the engine-ECU connector.
3. Measure the resistance and check for continuity between the terminal of the engine-ECU harness-
side connector while referring to the check chart.
NOTE
(1) When measuring resistance and checking continuity, a harness for checking contact pin pressure
should be used instead of inserting a test probe.
(2) All the sensors must be in room temperature 27 °C (80.6 °F) and at adle position.
(3) Check need to be carried out in the order given in the chart.
CAUTION
T
If the terminals that should be checked are mistaken, or if connector terminal are not correctly
shorted to earth, damage may be caused to the vehicle wiring, sensors, engine-ECU and/or ohmmeter.
Be careful to prevent this!
AF
(4) If the ohmmeter shows any deviation from the standard value, check the corresponding sensor,
actuator and related electrical wiring, and then repair or replace.
(5) After repair or replacement, recheck with the ohmmeter to confirm that the repair or replacement
has corrected the problem.
R
D
DOIQC13AR11114
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
16 – 8 Throttle actuator Less than5 Ω
19 – 12 Accelerator pedal sensor – 1 1.1 kΩ ± 0.6 kΩ

FUEL <CFE> 13A
Terminal No.
(harness side)
35 – 36 Crank sensor 650 Ω ± 130 Ω
50 – 34 Knock sensor More than1000 kΩ
95 – 63 Front oxygen sensor 4.5 Ω ± 0.5 Ω
93 – 63 Tank purge valve 26.0 Ω ± 5.2 Ω
90 – 63 Injector – 1
12.0 Ω ± 2.4 Ω
48 – 63 Ignition coil – 1
Less than1.0 Ω
COMPONENT LOCATION
T
AF
R
D
DOIQC13AR12003
Name Indication Location

CVT backup relay RPR A
Waste gate control WGC B
Relieve valve (Boost dump valve) BDR C

13A FUEL <CFE>

Recirculation pump RP D
Oil control valve OCV E
Map sensor 2 MAP2 F
VIEW LOCATION
A B
C
DOINC13AR11003
T
D
DOINH003R11012
AF
R
D
DOINH003R11013 DOINH003R11014
E F
DOINH003R11015 DOINH003R11006

FUEL <CFE> 13A
WASTE GATE CONTROL WCH13ASPROC11009
CAUTION
Be careful not to touch the connector (resin
section) with the tool when removing and in-
stalling the sensor.
1. Disconnect the connector harness.
2. Measure the resistance between terminal 1
and terminal 2.
Item Description
Terminal check terminal 1 and terminal
DOINH13AR11111
2
Standard value 23.0 Ω ± 1.2 Ω
3. If the resistance deviates from the standard
value, replace the sensor.
RELIEVE VALVE (BOOST DUMP VALVE)
CAUTION
T section) with the tool when removing and in-

stalling. Make sure the engine stops from run-
ning when replacing or connecting the compon-
AF
ent.
1. Remove the connector harness.
and 2.
Item Description
DOINH13AR11112
R
Terminal check terminal 1 and termin-

al 2
Standard value 13.2 ± 0.5 Ω
D
value, replace the valve.

RECIRCULATION PUMP
CAUTION
ent.
and 2.
Item Description
DOINH13AR11113
Terminal check terminal 1 and termin-
al 2
Standard value 13.2 ± 0.5 Ω
value, replace the pump.

13A FUEL <CFE>
OIL CONTROL VALVE

CAUTION
ent.
2. Measure the resistance between terminal
and 2.
Item Description
DOINH13AR11114
Terminal check terminal 1 and terminal
2
Standard value 7.2 Ω ± 0.5 Ω
3. If the resistance deviates with the standard
value, replace the sensor.
T
AF
R
D

FUEL <CFE> 13A
INJECTOR / 195
INJECTOR WCH13ASASSY11005
T
AF
R
DOIME11AR11005
D
— Lubricate all O-rings injector with engine oil during reassembly

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

13A FUEL <CFE>
/ 196 INJECTOR
2. While turning the injector and high-pressure fuel hose to the right and left, install the delivery
pipe, while being careful not to damage the O-ring. After installing, check that the hose turns
smoothly.
3. If it does not turn smoothly, the O-ring may be trapped, remove the fuel rail pressure and then
reinsert it into the delivery pipe and check once again.
T
AF
R
D

FUEL <CFE> 13A
INJECTOR / 197
REMOVAL OF INJECTORS
1. Remove the injector clip using screw driver.
2. Pull out the injector from fuel rail. Take care
not to drop the injectors.
Symbol Description
A Injector clip
B Fuel rail
C Injector
DOINE11AR11037 D Screw driver

NO-RETURN VALVE INSTALLATION
Before install the no-return valve, ensure the
arrow direction to electronic throttle body.
T Symbol
A
B
Description
No-return valve
Arrow
AF
DOIME11AR07014
INSTALLATION OF INJECTORS
1. Fit a new O-ring, on the injector.
R
Symbol Description
A O-ring
D
2. Coat the O-ring with spindle oil.

CAUTION :
(1) Be sure not to let spindle oil get into the
fuel rail.
(2) Beware not to insert injector slantingly.
DOIME13BR07004
3. Insert the injector top end onto the fuel rail

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

13A FUEL <CFE>
/ 198 INJECTOR
4. Install a new injector clip by sliding the open

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

FUEL <CFE> 13A
ECU / 199
ECU WCH13ASASSY11006
T
AF
R
DOIMC13AR11109
D
Pre-removal and Post-installation operation

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

13A FUEL <CFE>
/ 200 ECU
FLOOR CONSOLE REMOVAL

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

or).
AF
R
D
DOIMC023R11176

connector lock.
DOIMC023R11183

FUEL <CFE> 13A
ECU / 201
4. Disconnect the ECU connector (big connect-

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

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

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

13A FUEL <CFE>
/ 202 FUEL TANK
FUEL TANK WCH13ASASSY11009
T
AF
R
DOINC13AR08001
D
• Draining the fuel.
• Reduce the inner pressure of fuel line and hose. (Refer to On-Vehicle Sevice: Fuel pressure check)
• Remove the rear seat (Refer to MODULE 1.10, GROUP 52A — REAR SEAT).
• Remove the exhaust pipe (Refer to MODULE 1.3, GROUP 015 — EXHAUST PIPE).
• Remove pressure, return and purge tube, and levelling and filler hose (Refer to page
WCH13ASPROC407)
• Install pressure, return and purge tube, and levelling and filler hose.
• Install the exhaust pipe (Refer to, MODULE 1.3, GROUP 015 — EXHAUST PIPE).
• Install the rear seat (Refer to, MODULE 1.10, GROUP 52A — REAR SEAT).
• Refilling the fuel.
• Checking the fuel leaks.

FUEL <CFE> 13A
FUEL TANK / 203
Removal steps 8. Tube assy purge

1. Tube assy return 9. Tube assy vapour
2. Tube assy main 10. Cannister assy
3. Fuel tank assy 11. Tube roll over valve assy
4. Braket pump 12. Gasket roll over valve
5. Fuel pump module 13. Fuel filter assy
6. Hose, leveling 14. Heater protector assy
7. Hose filler
T1: 0.4~0.6 Kgf.m
T2: 0.2~0.3 Kgf.m
T3: 0.3 Kgf.m
T
AF
R
D

13A FUEL <CFE>
/ 204 FUEL TANK
PRE REMOVAL SERVICE POINT

WCH13ASPROC11014
FUEL TANK ASSY PRE REMOVAL

1. Remove the hose levelling clamp and hose
filler clamp.
Symbol Description
A Hose levelling clamp
B Hose filler clamp
DOINC13AR08003
2. Remove the brake cable bracket (RH) and

(LH) as shown in the illustration.
Symbol Description
A Brake cable bracket
T
AF
DOINC13AR08004
3. Disconnect the pressure tube from fuel filler

assy.
R
Symbol Description
A Fuel filler assy
B Pressure tube
D
(marked with red tag)
DOINC13AR08010
4. Disconnect the purge tube from canister

tube.
Symbol Description
A Purge tube
(marked with yellow tag)
B Tube to canister
DOINC13AR08011

FUEL <CFE> 13A
FUEL TANK / 205
5. Disconnect the purge return tube from canis-

ter tube.
Symbol Description
A Purge return tube
(marked with green tag)
B Tube to canister
DOINC13AR08012
6. Remove the bolts (LH) and (RH) to release

the strap assy bolts.
Symbol Description
A Strap assy bolt
T
AF
DOINC13AR08006
7. Carefully lift down the fuel tank module.

NOTE:
Cover the hoses connection with rags to
R
prevent of fuel residual in the fuel pipe line

from flowing out.
D
DOINC13AR08013

13A FUEL <CFE>
/ 206 FUEL TANK
NOTE
T
AF
R
D

FUEL <IAFM+> 13A
Content /1
13A FUEL <IAFM+>

GENERAL SPECIFICATION .......................................................... 13A/6
SPECIAL TOOLS ........................................................................ 13A/6
SERVICE SPECIFICATION ............................................................. 13A/8

SEALANT .............................................................................. 13A/8

FREEZE FRAME DATA ............................................................... 13A/8
DISPLAY ITEM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/9
FAIL-SAFE/BACKUP FUNCTION TABLE ........................................... 13A/10
READ OUT OF MALFUNCTION CODE ........................................... 13A/11
PRECAUTION FOR OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/11
CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS ....................... 13A/12
TURBO CHARGER PROBLEM SYMPTOM CHECK CHART .................... 13A/15
ENGINE WARNING LAMP .......................................................... 13A/21
ITEMS INDICATED BY THE ENGINE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/21
ENGINE WARNING LAMP INSPECTION .......................................... 13A/21
SELF-DIAGNOSIS .....................................................................
T
PADT- II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROBLEM DIAGNOSIS CONTENT CHART- IAFM+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13A/21
13A/21
13A/22
AF
INSPECTION CHART FOR DIAGNOSIS CODES .................................. 13A/31
INSPECTION PROCEDURE FOR DIAGNOSIS CODES ............................. 13A/36

CAMSHAFT SENSOR ................................................................ 13A/36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/36
FRONT OXYGEN SENSOR .......................................................... 13A/38
R

REAR OXYGEN SENSOR ............................................................ 13A/41
THROTTLE BODY ACTUATOR ..................................................... 13A/44
D
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/44
TMAP SENSOR (INTAKE AIR TEMPERATURE SENSOR AND VACUUM 13A/49
SENSOR) ...............................................................................
OPERATION INTAKE AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/49
COOLANT TEMPERATURE SENSOR .............................................. 13A/52
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/52
ACCELERATOR PEDAL SENSOR ................................................... 13A/55
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/55
OXYGEN CONTROL ................................................................. 13A/57
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/57
INJECTORS ............................................................................ 13A/60
FUEL PUMP RELAY .................................................................. 13A/63
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/63
MISFIRE ............................................................................... 13A/65
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/65

13A FUEL <IAFM+>
/2 Content

KNOCK SENSOR ..................................................................... 13A/68
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/68
CRANKSHAFT SENSOR ............................................................. 13A/71
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/71
TROUBLESHOOTING PROSEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/72
IGNITION COIL ....................................................................... 13A/73
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/73
CATALYTIC SYSTEM ................................................................. 13A/75
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/75
CANNISTER PURGE SOLENOID VALVE .......................................... 13A/77
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/77
ENGINE FAN .......................................................................... 13A/80
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/80
VEHICLE SPEED SIGNAL [ A/T ] ................................................... 13A/82
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/82
VEHICLE SPEED SIGNAL [ M/T ] ................................................... 13A/85
T
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE LIGHT SWITCH (Stop lamp switch) .....................................
13A/85
13A/87
13A/88
AF
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/89
ENGINE SPEED SIGNAL [ A/T ] .................................................... 13A/90
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/90
ENGINE SPEED SIGNAL [ M/T ] .................................................... 13A/93
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/93
R
IMMOBILISER ........................................................................ 13A/96

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/96
POWER SUPPLY ...................................................................... 13A/98
D
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/99
ENGINE CONTROL UNIT ........................................................... 13A/100
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/100
STARTER CONTROL ................................................................. 13A/102
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/102
SENSOR SUPPLY ..................................................................... 13A/104
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/104
AIR COND CLUTCH .................................................................. 13A/106
VIM (VACCUM ACTUATOR) [IAFM] .............................................. 13A/109
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/109
MAIN RELAY ......................................................................... 13A/111
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/112
TRANSMISSION CONTROL UNIT (CVT) .......................................... 13A/114
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/114
P/N SWITCH .......................................................................... 13A/116
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/116

FUEL <IAFM+> 13A
Content /3

PEDAL/BRAKE SWITCH ............................................................. 13A/118
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/119
CAN COMUNICATION .............................................................. 13A/121
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/121
TROUBLE SYMPTOM ................................................................. 13A/123

INSPECTION CHART FOR TROUBLE SYMPTOMS .............................. 13A/123
PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) ................. 13A/125
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS ......................... 13A/126

Communication with PADT-II is not possible (Communication with all systems is not 13A/126
possible ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PADT-II Communication with engine-ECU is impossible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/126
The engine warning lamp does not illuminate right after the ignition switch is turned 13A/127
to the ON position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T
The engine warning lamp remains illuminating and never goes out. . . . . . . . . . . . . . . . . . 13A/128
No initial combustion (starting impossible) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/129
AF
Initial combustion but no complete combustion (starting impossible) . . . . . . . . . . . . . . . . 13A/130
Takes too long time to start (Incorrect Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/131
Unstable idling (Rough idling, hunting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/132
Idling speed is high (Improper idling speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/133
R

Idling speed is low (Improper idling speed ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/134
When the engine is cold, it stalls at idling (Die out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/135
D

When the engine is hot, it stalls at idling (Die out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/136
The engine stalls when starting the car (Pass out) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/137
The engine stalls when decelerating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/138
Hesitation, sag or stumble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/139
The feeling of impact or vibration when accelerating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/140
The feeling of impact of vibration when decelerating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/141
Poor acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/142
Surge ................................................................................. 13A/143
Knocking ............................................................................. 13A/144
Dieseling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/145
Too high CO and HC concentration when idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/145

13A FUEL <IAFM+>
/4 Content

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

Check fuel pump motor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/163
D
Check the fuel pump relay drive circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/164

Check throttle body actuator (TBA) output circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/165
Check injector control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/166
Check ignition coil and power transistor unit circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/167
DATA LIST ............................................................................... 13A/168

DATA LIST REFERENCE TABLE ..................................................... 13A/168
ACTUATOR TEST ...................................................................... 13A/171

ACTUATOR TEST REFERENCE TABLE ............................................ 13A/171
CHECK AT THE ENGINE-ECU ........................................................ 13A/173

TERMINAL VOLTAGE CHECK CHART ............................................ 13A/173
ENGINE-ECU CONNECTOR TERMINAL ARRANGEMENT ..................... 13A/173
CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMIN- 13A/177
ALS .....................................................................................
INJECTOR ............................................................................... 13A/179

FUEL <IAFM+> 13A
Content /5

INJECTOR/HIGH-PRESSURE FUEL HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A/179
ECU ...................................................................................... 13A/183

FUEL TANK ............................................................................. 13A/186

PRE REMOVAL SERVICE POINT ................................................... 13A/188
T
AF
R
D

13A FUEL <IAFM+>
GENERAL SPECIFICATION
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
T
Engine coolant temperature sensor Thermistor type
Sensor Oxygen sensor Zirconia type
Vehicle speed sensor Magnetic resistive element type
AF
Inhibitor switch Contact switch type
Crank angle sensor Hall element type
Camshaft sensor
Knock sensor
Control relay type Contact switch type
R
Fuel pump relay Contact switch type

Injector type and number Electromagnetic type, 4
Actuators
Injector identification mark CDH210
D
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)
TOOLS
interface (VCI)
DOIMC35BR11039

FUEL <IAFM+> 13A
SPECIAL TOOLS /7

CD
DOIMC35BR11042

connector; 1 m) VCI
DOIMC35BR11041

USB cable (1.8 m)
T
PC and VCI
DOIMC35BR11046
AF
R
DOIMC35BR11045
D

Ethernet cable
ing to VCI
DOIMC35BR11040

Cable keeper
cable messy
DOIMC35BR11043

DOIMC35BR11044

13A FUEL <IAFM+>
/8 SERVICE SPECIFICATION
DOIMC35BR11047
SERVICE SPECIFICATION WCH13ASPECS11004
IAFM+
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
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)
kΩ 80 °C (176 °F)
T 2.3 - 3.0 kΩ
0.30 - 0.42 kΩ
AF
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)
R
tion at curb idle

Injector coil resistance Ω 13 - 16 Ω (at 20 °C (68 °F))
SEALANT
D

Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equival- Drying sealant
threaded portion ent
TROUBLESHOOTING WCH13ASHOOT11288
FREEZE FRAME DATA

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

FUEL <IAFM+> 13A
TROUBLESHOOTING /9
DISPLAY ITEM LIST

controlling fuel.
• Open Loop*1
• Close Loop*2
failure
sensor is failed
2 % -
value
3 °C -
ature
4
5
put
Fuel mass set point
factor
%
%
T -
-
AF
6 kPA -
sure
Front Oxygen Sensor
9 OFF / ON -
R
Status
Rear Oxygen Sensor
10 OFF / ON -
Status
D
Short Term Secondary

11 % -
O2 Sensor Fuel Trim
Long Term Secondary
12 % -
O2 Sensor Fuel Trim
13 DTC Failure byte - -
controlling fuel.
• Open Loop*1
• Close Loop*2
failure
sensor is failed
15 % -
value

13A FUEL <IAFM+>

16 °C -
ature
Fuel mass set point
17 % -
factor
18 % -
put
19 kPA -
sure
Relative throttle posi-
22 % -
tion
Ignition factor applier
23 °CRK -
on first cylinder
• Idle mode, idle contact
closed
• Full load mode
24 Engine status
•
•
SAS active
Throttle actuator limp
home mode
T -
AF
• Safety concept activated
• Fuel Shut off mode
Accumulated time of current malfunction
25 Time after start s from time point when malfunction is de-
tected
26 Fault status byte MIL On / MIL Off -
R
Number of DTC since

27 - -
last DTC clear command
Distance since DTC
28 km -
D
clearing
29
ing data
30 normal value = 0
ing data
- If display is different from normal value,
Safety level 2 monitor- replace ECU.
31
ing data
32
ing data
FAIL-SAFE/BACKUP FUNCTION TABLE WCH13ASHOOT11289
When the main sensor malfunctions are detected by the self-diagnosis function, the vehicle is controlled
by means of the pre-set control logic to maintain safe conditions for driving.
Malfunction item Control contents during malfunction

Intake air temperature sensor Controls as if the intake air temperature is 40 °C (104 °F)
Coolant temperature sensor Controls as if the coolant temperature is 80 °C (176 °F)

FUEL <IAFM+> 13A
Malfunction item Control contents during malfunction

No increase in fuel injection amount during acceleration due
Throttle body actuator (TBA)
to the throttle position sensor signal
1. Injects fuel into the cylinders in the order 1-3-4-2 with
irregular timing (However, after the ignition switch is
Camshaft sensor
turned to ON, the No. 1 cylinder top dead center is not
detected at all)
Combined map & mat sensor Use TPS signal as back-up
Air/Fuel ratio feedback control (closed loop control) is not
Oxygen sensor
performed
READ OUT OF MALFUNCTION CODE
PRECAUTION FOR OPERATING
1. When battery voltage is low, no detection
of failure is possible. Be sure to check the
battery for voltage and other conditions be-
fore starting the tests.
2. Connection and disconnection of the PADT–II
should always be made with the ignition
T switch in the OFF position.

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

1. Read and make a note of the self-diagnosis
output.
R
2. Repair the problem location, referring to the

diagnosis chart.
3. After turning the ignition switch once to OFF,
turn it back to ON.
D
4. Erase the malfunction code.

5. Recheck to be sure that the condition is nor-
mal.
Symbol Description
DOIMC13AR11111
PADT-II vehicle commu-
A
nication interface ( VCI )
B OBD-II cable
C USB cable
NOTE
For details information on the PADT-II, please
refer to the PADT-II User Manual.

13A FUEL <IAFM+>
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
T
Fuel ∇3 ∇1 ∇1 ∇1 ∇1
pump #3 #1 #1 #1 #1
Intake
AF
air tem-
pera-
∇5 ∇4 ∇2
ture ∇5
#5 #4 #2
sensor –
Mat
sensor
Vacuum
R
sensor
(Mani-
fold ab-
∇8 ∇6 ∇3
D
solute ∇7
#8 #6 #3
pressure
sensor –
Map
sensor
Coolant
tem-
∇6 ∇1 ∇5 ∇7 ∇5 ∇4 ∇3
pera- #3
#5 #1 #5 #7 #5 #4 #3
ture
sensor
Cam-
∇5 ∇5 ∇8 ∇2
shaft
#5 #6 #7 #2
sensor
Crank-
∇6 ∇6 ∇9 ∇3
shaft
#6 #7 #8 #3
sensor
Ignition
∇4 ∇3
switch-
#4 #4
ST (M/T)

FUEL <IAFM+> 13A
Problem
Stoppi-
symp- Starting Idling stability Driving
ng
toms
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
Air con-
ditioner
switch
and
power
∇2
T
AF
relay
Oxygen
∇10
sensor
Throttle
∇4 ∇1 ∇5 ∇2 ∇6 ∇3 ∇4
body ac-
#5 #1 #3 #2 #6 #3 #4
tuator
R
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
D
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)

13A FUEL <IAFM+>
NOTE
T
AF
R
D

TURBO CHARGER PROBLEM SYMPTOM CHECK CHART WCH13ASHOOT11290
Problem symptom
Engine Drag or Damaged
Excessive Excessive Excessive Excessive Solutions
lacks Black Blue bind in com- Damage tur- Possible cause
oil con- Noise oil-com- oil-turbine rotating
of smoke smoke rotating pressor bine wheel
sumption pressor end end assy play
power assy wheel
Dirty air Clean or re-
X X X X X cleaner ele- place filter ele-
ment ment
Pugged crank Clear obstruc-
X X X
case breathers tion
Air cleaners
Replace, repair
element miss-
X
D X X ing leaking or
or reconnect
air cleaner ele-
loose connec-
ment
tion to turbo
R Collapsed or
restricted air
X X X X X
pipe before
turbo Inspect pipe for
damage or ob-
Restricted or struction, re-
damages cros- place or repair

X X X X sover pipe
AF
turbo to inlet
manifold
Foreign object Inspect air in-
X X X X X X
T X
between take piping, re-
cleaner and move foreign
turbocharger object
Inspect exhaust
Foreign object piping only
in exhaust sys- when engine is
FUEL <IAFM+>
X X X X X X X tem (from en- not running

gine, check and cold, re-
engine) move foreign
object
/ 15
13A
Problem symptom / 16
13A

power assy wheel
Inspect all con-
necting hard-
Turbocharger
ware for dam-
X X X X X X X X X X X flanges clamp
age. Ensure fit
or bolt loose
as per installa-
tion instruction
FUEL <IAFM+>
Remove ex-
haust manifold
Inlet manifold only when en-
D cracked, gine is clod and
burned, gas- nor running,
X X X
ket loose, and inspect for
blown or miss- damage to
R ing casting and
gaskets, re-
place if needed
Inspect exhaust
system only
when engine is
Restricted ex-

X cold and not
AF
haust system
running. Re-
move obstruc-
tion
T Oil lag at Inspect lubrica-
X X
start-up tion system
lines, filters
and oil for ob-
Insufficient struction. Re-
X X
lubrication move obstruc-
tion
Problem symptom
power assy wheel
Lubricating oil
Replace all fil-
contaminated
X X ters and lubric-
with dirt or
ating oil
other material
Improper oil Replace lubrica-
X X lubrication oil tion with the
is used correct grade
X X X X
D feed line spect oil line.
Restricted oil Remove ob-
X X struction
drain line
R Remove tur-
bine housing.
Turbine hous-
Inspect for
X X X X ing damaged
cracks or wear.
or restricted
Replace if
needed
Inspect for

AF
Turbocharger proper oil feed/
X X X X
seal leakage drain line in-
stallation
X X X X X X X X
T X X
Worn journal
bearing
FUEL <IAFM+>
/ 17
13A
13A

power assy wheel
Inspect air
cleaner ele-
ment and in-
take piping for
Excessive dirt
damage or
build-up be-
X X X X X X X X leakage. Re-
FUEL <IAFM+>
hind turbine
place if
wheel
needed. Clean
compressor
D wheel and
housing
Excessive car-
bon build-up Inspect crank-
X X X X
RX X X on com- case ventilation
pressor hous- system
ing
Too fast accel- Decrease accel-
X X erating at ini- eration at ini-
tial start tial start-up

AF
Too little Extend warm
X X
warm up time up period
Inspect fuel
Fuel pump
X X
T malfunction
pump for dam-
age
Worn or dam- Inspect inject-
X X
aged injectors ors for damage
X X Valve timing Adjust if need
Replace if
X X Burned valves
needed
Worn piston Replace if
X X
rings needed
Problem symptom
power assy wheel
Burned pis- Replace if
X X
tons needed
Remove and in-
Leaking oil spect oil line.
X X
feed line remove obstruc-
tion
Excessive en- Adjust if
X X
gine pre-oil needed
X X X
D X
Excessive en- Adjust if
gine idle needed
Coked or
X X
RX X X sludged cen-
ter housing
Oil pump mal- Replace if
X
function needed
Oil filter Replace if
X X X X X X X X
plugged needed

Oil bath air
AF
cleaner. Air
inlet screen Replace air in-
X X X X X
restricted / let screen
T dirty air clean-
er
Oil bath air
cleaner. Oil Replace lubric-
X X X X X pull-over/ oil ating oil with
viscosity too correct grade
FUEL <IAFM+>
low or high
/ 19
13A
13A

power assy wheel
Inspect for
Boost control damage, leaks,
X X X X X X X X X X malfunction obstruction.
wastegate Replace or re-
pair if needed
FUEL <IAFM+>
D
R

AF
T
FUEL <IAFM+> 13A
/ 21
ENGINE WARNING LAMP WCH13ASHOOT11291
Among the self-diagnosis items, an engine

warning lamp comes on to notify the driver of
the emission control items when an irregularity
is detected.
Symbol Description
Malfunction indicator lamp
A
(MIL)
ITEMS INDICATED BY THE ENGINE WARNING
LAMP
Engine control unit
Front oxygen sensor
Combined map & mat sensor
Crankshaft sensor
Camshaft sensor
DOIQC13AR11001
Tank purge valve
T
Throttle body actuator
Detonation/knock sensor
Ignition coil
AF
ENGINE WARNING LAMP INSPECTION
1. Check that when the ignition switch is turned ON, the lamp illuminates.
2. If the lamp does not illuminate, check for open circuit in harness, blown fuse and blown bulb.
3. If the MIL does not illuminate and no “Clicking” sound of power relay is heard, then ECU or power
R
supply to ECU is faulty. Check power supply to ECU (blown diode, blown fuse, harness) or replace
ECU.
SELF-DIAGNOSIS
D
The engine control unit monitors the input/output signals (some signals at all times and the others
under specified time or longer) from when the irregular for a specified time or longer from when the
irregular signal is initially monitored, passing a certain number, the engine control unit judges that
an irregularity has occured, memorizes the malfunction code, and outputs the signal to the self-dia-
gnosis output terminal. There are 16 items connector output terminal. There are 16 pins diagnosis
items, and the diagnosis results can be read out with a PADT- II. Moreover, since memorization of the
malfunction codes is backed up directly by the battery, the diagnosis results are memorized even if
the ignition key is turned off. The malfunction code can only be erased turning the ignition switch
to ON and sending the malfunction code erase signal from the PADT- II to the engine control unit.
PADT- II
Diagnosis Chart
NOTE
• Replace the engine control unit if malfunction code is output although the inspection reveals that
there is no problem with the check items.

13A FUEL <IAFM+>
/ 22
PROBLEM DIAGNOSIS CONTENT CHART- IAFM+

CODE IS ITEM TION
Enduring camshaft position
P0011 tion deviation at steady change for diagnosis at
deviation at steady setpoint
setpoint steady setpoint
Camshaft sensor not syn-
Cam_in violation of Intake camshaft position
chronise with crankshaft
crk_ref out of range
P0016 reference
Intake camshaft drift from Intake I one-tooth-off Intake camshaft drift of
position diagnosis position
Camshaft Intake camshaft diagnost-
Intake camshaft diagnostic
ic for engine synchroniza- Plausibility
for engine synchronization
P0340 tion
Intake camshaft synchroniz- Intake camshaft synchron- Intake camshaft syn-
ation diagnosis ization diagnosis chronization loss
Intake camshaft signal Intake camshaft signal Intake camshaft signal
P0341
plausibility plausibility implausible
P0344
gnosis
T
Intake camshaft period dia- Intake camshaft period Intake camshaft period
diagnosis
out of range
AF
P0030 Open circuit
open circuit heater obdi diagnosis
P0031 Short circuit to gnd
short circuit to ground heater obdi diagnosis
short circuit to battery heater obdi diagnosis
Upstream oxygen sensor Lambda sensor heater
R
P0053 Heater fault

heater fault fault
Front oxygen sensor open Upstream oxygen sensor Open circuit / circuit
P0130
circuit signal diagnosis open
D
Front Oxy-
Front oxygen sensor short Upstream oxygen sensor
P0131 gen Short circuit to ground
circuit to ground signal diagnosis
Sensor
System Front oxygen sensor short Upstream oxygen sensor
circuit to battery signal diagnosis
Front oxygen sensor circuit Frequency diagnosis up-
P0133 Frequency too small
slow response stream
Front oxygen sensor not Upstream oxygen sensor Sensor not ready / no
P0134
ready signal diagnosis signal
Front oxygen sensor signal Upstream oxygen sensor Signal excursion not
P0134
excursion not plausible signal diagnosis plausible / signal erra
Oxygen Sensor Signal dur-
Upstream oxygen sensor Signal during fuel cut-
P2297 ing fuel Cut Off not Plaus-
signal diagnosis off not plausible
ible

FUEL <IAFM+> 13A
/ 23

CODE IS ITEM TION
open circuit
gnosis gnosis
gnosis gnosis
gnosis gnosis
Downstream oxygen sensor Lambda sensor heater
P0054 Heater fault
open circuit fault
Rear Oxy- Rear oxygen sensor open Downstream oxygen
P0136 gen Open circuit
circuit sensor signal diagnosis
Sensor
System Rear oxygen sensor short Downstream oxygen
circuit to ground sensor signal diagnosis
Rear oxygen sensor short Downstream oxygen
T
circuit to battery sensor signal diagnosis
Downstream Oxygen
Rear Oxygen Sensor Signal Rear Oxygen Sensor Sig-
P2270 Sensor rich voltage
Stuck Lean nal Stuck Rich
AF
threshold check
Downstream Oxygen
Rear oxygen sensor signal signal high during fuel
P2271 Sensor lean voltage
stuck rich cutoff
threshold check
Rear oxygen sensor signal Signal plausibility monit- Signal high during fuel
P2A01
high during fuel cut off oring cutoff
R
D

13A FUEL <IAFM+>
/ 24

CODE IS ITEM TION
Throttle position sensor / Load Sensor Failure or
P0068 TPS diagnosis
Throttle body failure Throttle Failure
Fuel System Leak Detected Load/TPS plausibility out of MAX
P0093
– Large Leak check PUT controller out of
max, Lambda out of
MAX,
Fuel System Leak Detected Load/TPS plausibility out of Min
P0094
– Large Leak check
max, Lambda out of Min
Intake Air System Restric- Load/TPS plausibility between Min, MAX
P1121
T
tion check PUT controller out of
max, Lambda between
Min, MAX
AF
P0101 TPS diagnosis Load Sensor Failure
failure
P0121 TPS diagnosis Throttle Failure
Throttle Diagnostic
Body Actu- Voltage Throttle Position electric position sensor
P0122 ator position sensor 1 low
Sensor 1 Low diagnosis
R
Voltage Throttle Position electric position sensor

Sensor 1 High diagnosis
D
Sensor 2 Low diagnosis

Sensor 2 High diagnosis
Throttle Actuator Controller check of lower return error lower return spring
lower return spring error spring of ETC check
P1588
Throttle Actuator Controller check of upper return error upper return
upper return spring error spring of ETC spring check
Ambient Pressure adapta-
load sensor or throttle
P169F tion error, Throttle Position TPS diagnosis
or AMP failure
Sensor error
P2100 open circuit
open circuit is
P2101 short circuit
short circuit is
Throttle Position Sensor check of lower mechanic- lower position not
P2109
Lower position not Reached al stop of ETC reached
over heat protection is

FUEL <IAFM+> 13A
/ 25

CODE IS ITEM TION
ETC position controller PWM exceeds threshold
Throttle Actuator Controller output monitoring 1
output position monitoring ETC position controller PWM exceeds threshold
output monitoring 2
P2119
check of lower mechanic- lower mec. stop adapta-
Throttle Actuator Controller al stop of ETC tion outside range
Deviation exceed Threshold ETC control deviation control deviation ex-
diagnosis ceeds threshold
Throttle/Pedal Ratio
Ratio check
check
TPS – MAF plausibility
Throttle/Pedal Position TPS1 plaus error
P2135 check
plausibility
TPS – MAF plausibility
TPS2 plaus error
check
TPS rationality check TPS ratio error
Throttle Position Sensor check of upper mechanic- upper position not
T
P2163
Upper Position not Reached al stop of ETC reached
check of adaptation con- adaptation conditions
AF
dition exceeded
Threshold
Limp-home Adaptation check of TPS limp home limp-home adaptation
P2176
Outside Range position outside range
between Min, MAX
R

min, Lambda between
Min, MAX
D

P2280
max, Lambda controller
not enable
Load/TPS plausibility
Air Leak Between MAF and check
Throttle Body
of Max
Throttle Body
P2281 of Min
min, Lambda out of
Throttle Body
MAX
Air Leak Between MAF and PUT controller out of
Throttle Body min, Lambda out of Min
Air Leak Between Throttle
P2282
Body and Intake Valves

13A FUEL <IAFM+>
/ 26

CODE IS ITEM TION
min, Lambda controller
not enable
Manifold air pressure sensor Manifold air pressure Signal line short to
P0102
short circuit to ground sensor diagnosis ground
Manifold air pressure sensor Manifold air pressure Signal line short to bat-
P0103
short circuit to battery sensor diagnosis tery voltage
Manifold absolute pressure Manifold pressure plaus- Manifold pressure not
P0106
not plausible (MAP) ibility plausible
P0111 TMap TIA stuck signal diagnosis Stuck TIA signal
Sensor plausibility
Sensor
TIA signal electrical dia- Signal short circuit to
gnosis ground
T
ground
Intake Air Temperature TIA signal electrical dia-
P0113 Signal open circuit
Sensor 1 open Circuit gnosis
AF
Ambient pressure plausibil- Ambient pressure plausib- Ambient pressure not
P2227
ity ility plausible
Coolant temperature sensor Coolant temperature sig-
P0117 Coolant Short circuit to ground
short circuit to ground nal range diagnosis
Temperat-
Coolant temperature sensor Coolant temperature sig- Short circuit to vbatt or
P0118 ure
open circuit nal range diagnosis open circuit
R
Sensor
System Coolant temperature signal Coolant temperature sig- Coolant temperature
P0119
gradient error nal range diagnosis signal gradient error
P0122 Pedal voltage sensor 1 low Pvs_1 out of range check Pedal Voltage 1 low
D
P0123 Accelerat- Pedal voltage sensor 1 high Pvs_1 out of range check Pedal Voltage 1 high
or Pedal
P0222 Sensor Pedal voltage sensor 2 low Pvs_2 out of range check Pedal Voltage 2 low
P0223 Pedal voltage sensor 2 high Pvs_2 out of range check Pedal Voltage 2 high
Fuel system diagnosis for Maximum limit of
Maximum limit of Lambda
oring reached
P0171
Maximum limit of adapta- Maximum limit of adapt-
Oxygen itoring
Control Fuel system diagnosis for Minimum limit of
Minimum limit of Lambda
oring reached
P0172
Minimum limit of adapta- Minimum limit of adapt-
itoring

FUEL <IAFM+> 13A
/ 27

CODE IS ITEM TION
Injector Circuit/Open – Cylin- Injection valve diagnostic
der 1 - open circuit
P0261
P0262
Injector cuit to battery - short circuit plus plus
System Cylinder 2 Injector short cir- Injection valve diagnostic Cylinder 2 short circuit
P0264
P0265
P0267
Cylinder 3 Injector short cir-
cuit to ground
Cylinder 3 Injector short cir-
TInjection valve diagnostic
- short circuit ground
Injection valve diagnostic
Cylinder 3 short circuit
ground
Cylinder 3 short circuit
AF
P0268
P0270
P0271
Fuel Pump Relay Open Cir- Fuel pump electrical dia-
R
P025A Open circuit

cuit gnostic
Fuel
P025C Pump Re- Short circuit to ground
cuit to Ground gnostic
D
lay
P025D Short circuit to battery
cuit to Battery gnostic
Random/multiple cylinder Random or multiple mis-
P0300 Plausibility
misfire detected fire diagnosis
P0301 Cylinder 1 misfire detected Misfire diagnosis Misfire on cylinder 1
Misfire
Knock acquisition chain
P0324 Knock control system error Knck spi failure
diagnosis
Knock
Basis knock signal dia-
P0325 Sensor Knock sensor error Knck sensor basic failure
gnosis
System
Relative knock signal dia- Relative knock signal Knck sensor relative fail-
P0326
gnosis diagnosis ure

13A FUEL <IAFM+>
/ 28

CODE IS ITEM TION
Crankshaft sensor failure Crankshaft sensor failure Crankshaft sensor failure
P0335 open or short circuit dia- open or short circuit dia- open or short crk_oc cir-
gnosis gnosis cuit
Crankshaft signal miss-
Crankshaft signal missing Crankshaft signal missing
ing
Crank- Crankshaft signal implaus- Crankshaft signal implaus- Crankshaft signal im-
shaft ible ible plausible
Sensor Crankshaft loss of synchron- Crankshaft loss of syn- Crankshaft synchroniza-
P0336
ization diagnosis chronization diagnosis tion lost
Crankshaft tooth number Crankshaft tooth number Wrong crankshaft tooth
error diagnosis error diagnosis number
Crankshaft tooth period Crankshaft tooth period Crankshaft tooth period
diagnosis diagnosis out of range
Open circuit
P0354
P2300
Ignition Coil 4 open circuit
T Short circuit to ground

AF
to ground
to battery
Ignition Ignition Coil 3 short circuit
Coil Sys- to ground Ignition Diagnosis
tem Ignition Coil 3 short circuit
R
to battery
to ground
D

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

FUEL <IAFM+> 13A
/ 29

CODE IS ITEM TION
P0480 Fan 1 Open circuit Open circuit Fan 1 Open circuit
Fan 1 Short circuit To Fan 1 Short circuit To
P0691 Engine Short circuit to ground
ground ground
fan
Fan 1 Short circuit To Bat- Fan 1 Short circuit To
tery Battery
Electrical diagnosis of vs
P0500 Vehicle Vehicle speed sensor Vs sensor defective
sensor
speed
sensor Vehicle speed correlation Electrical diagnosis of vs
P215A Vs can not valid
not valid can
Brake
BLS-BTS check detected
P0504 light Brake Switch Error Plausibility
error
switch
Engine speed at idle is be-
P0506 low calculated idle speed Present isc_low failure
Engine too low
target
speed
sensor Engine speed at idle is
P0507 above calculated idle speed
target
T too high
immobilizer failure due

Present isc_high failure
AF
P0513 Immobilizer locked to wrong authentication Wrong transponder
Immob- process
ilzer immobilizer failure due
Communication with
P0633 to no communication Transponder missing
transponder missing
with transponder
P0562 Battery voltage too low Battery voltage too low Battery voltage too low
R
P0563 Power Battery voltage too high Battery voltage too high Battery voltage too high
Supply Battery voltage too high Battery voltage too high Battery voltage too high
P1793
Battery voltage too low Battery voltage too low Battery voltage too low
D
ECU Warm-reset diagnos- ECU Warm-reset diagnos-

P0604 ECU Warm Reset
is is
P0606 ECU Internal Fault SPI Bus communication ECU Monitoring
P060A ECU Internal Fault - General General monitoring General monitoring
ECU Internal Fault - Pro- Processor monitoring
P060C ECU Monitoring
cessor monitoring failure
ECU
Actual or requested
Torque intervention for Torque intervention for
P061A torque higher than al-
safety active satety active
lowed limit
P061B Torque monitoring Torque monitoring Torque monitoring
Internal Control Module
P061C N_LIM monitoring ECU internal Monitoring
Engine RPM Performance
P0615 Starter relay open circuit Starter relay Open circuit
P0616 Starter Starter relay Short circuit to ground
ground
Control
P0617 Starter relay Short circuit to battery
battery

13A FUEL <IAFM+>
/ 30

CODE IS ITEM TION
“A” Circuit Low
Sensor “A” Circuit High
Supply Sensor Reference Voltage
“B” Circuit Low
“B” Circuit High
Air condition clutch, open
P0645 Open circuit
circuit
Air cond Air condition clutch, short Air conditioning com-
clutch circuit to ground pressor diagnosis
Air condition clutch, short
circuit to battery
VIM Actuator open cir-
P0660
cuit
P0661
VIM Actu-
ator
VIM Actuator Electrical
Power Stage Diagnosis
T
VIM Actuator Electrical
Power Stage Diagnosis
VIM Actuator short cir-
cuit
to ground
AF
VIM Actuator short cir-
P0662
cuit
Main relay input Open Cir- Main relay input OL elec- Main relay input Open
P0685
cuit trical diagnosis Circuit
Main relay input Short cir- Main relay input SCG Main relay input Short
P0686
cuit to Ground electrical diagnosis circuit to Ground
R
Main relay input Short cir- Main relay input SCP Main relay input Short
P0687
Main re- cuit to Battery electrical diagnosis circuit to Battery
lay Main relay ON output dia- Main relay ON output Main relay ON output
D
P0689
Main relay OFF output dia- Main relay OFF output Main relay OFF output
P0690
Main relay switch ON too Main relay switch ON too Main relay switch ON
P2510
slow slow too slow
Transmission control unit Transmission control unit
P0700 TCU Transmission Limp Home
limp home diagnosis limp home diagnosis
Hard wired P/N switch
P0850 P/N switch P/N switch plausibility Plausible value
diagnosis
Pedal / Brake Pedal Position/Accel-
P2299 Brake erator Pedal Position Incom- Plausibilty brake error Plausibility
Switch patible

FUEL <IAFM+> 13A
/ 31

CODE IS ITEM TION
U0073 CAN diagnosis - buss off Can diagnosis Can bus off
U0100 Can diagnosis for ecu
nication with ECU nicating on the can-hs
bus
U0101 Can diagnosis for tcu
CAN com- nication with TCU nicating on the can-hs
munica- bus
tion Error in the respective
U0121 Can diagnosis for abs
nication with ABS/ESP nicating on the can-hs
bus
U0140 Can diagnosis for icu
nication with meter cluster nicating on the can-hs
bus
INSPECTION CHART FOR DIAGNOSIS CODES

T WCH13ASHOOT11292
AF
FAULT CODE Diagnosis items Reference page
P0011
P0016
P0340 Camshaft Sensor 13A/36
P0341
R
P0344
P0030
P0031
D
P0032
P0130
P0131
Front Oxygen Sensor System 13A/38
P0132
P0133
P0134
P0053
P2297

13A FUEL <IAFM+>
/ 32

P0036
P0037
P0038
P0136
P0137
Rear Oxygen Sensor System 13A/41
P0138
P2A01
P0054
P2270
P2271
P0093
P0094
P0068
P1121
P2176
P0101
P0121
P0122
T
AF
P0123
P0222
P0223
P1588
P169F Throttle Body Actuator System 13A/44
R
P2100
P2101
P2109
D
P2118
P2119
P2135
P2163
P2176
P2279
P2280
P2281
P2282
P0102
P0103
P0106
P0111 TMap Sensor 13A/49
P0112
P0113
P2227

FUEL <IAFM+> 13A
/ 33

P0117
P0118 Coolant Temperature Sensor System 13A/52
P0119
P0122
P0123
Accelerator Pedal Sensor 13A/55
P0222
P0223
P0171
Oxygen Control 13A/57
P0172
P0201
P0202
P0203
P0204
P0261
P0262
Injectors System 13A/60
P0264
P0265
P0267
T
AF
P0268
P0270
P0271
P025A
P025C Fuel Pump Relay 13A/63
R
P025D
P0300
P0301
D
P0302 Misfire 13A/65

P0303
P0304
P0324
P0325 Knock Sensor System 13A/68
P0326
P0335
Crankshaft Sensor 13A/71
P0336

13A FUEL <IAFM+>
/ 34

P0351
P0352
P0353
P0354
P2300
P2301
Ignition Coil System 13A/73
P2303
P2304
P2306
P2307
P2309
P2310
P0420 Catalytic Converter 13A/75
P0444
P0458 Cannister Purge Solenoid Valve 13A/77
P0459
P0480
P0691 Engine Fan
T 13A/80
AF
P0692
P0500
Vehicle Speed Signal (A/T) 13A/82
P215A
P0500
Vehicle Speed Signal (M/T) 13A/85
P215A
R
P0504 Brake Light Switch 13A/88

P0506
Engine Speed Signal (A/T) 13A/90
P0507
D
P0506
Engine Speed Signal (M/T) 13A/93
P0507
P0513
Immobilizer 13A/96
P0633
P0562
P0563 Power Engine Control Unit 13A/98
P1793
P0604
P0606
P060A
P060C Engine Control Unit 13A/100
P061A
P061B
P061C

FUEL <IAFM+> 13A
/ 35

P0615
P0616 Starter Control 13A/102
P0617
P0642
P0643
Sensor Supply 13A/104
P0652
P0653
P0645
P0646 Compressor 13A/106
P0647
P0660
P0661 Vacuum Actuator 13A/109
P0662
P0685
P0686
P0687
P0689
P0690
Main Relay
T 13A/111
AF
P2510
P0700 Automatic Transmission Control Unit 13A/114
P0850 P / N Switch 13A/116
P2299 Pedal / Brake Switch 13A/118
U0073
R
U0100
U0101 CAN Interface 13A/121
U0121
D
U0140

13A FUEL <IAFM+>
INSPECTION PROCEDURE FOR DIAGNOSIS CODES WCH13ASHOOT11293
CAMSHAFT SENSOR
T
AF
R
D
DOIQC13AR11002
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

FUEL <IAFM+> 13A
Check condi-
tion
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
T
diagnosis out of range ning
AF
R
D
DOIQC13AR11003

13A FUEL <IAFM+>
FRONT OXYGEN SENSOR WCH13ASHOOT11294
T
AF
R
D
DOIQC13AR11004
OPERATION

FUEL <IAFM+> 13A
Fault
PADT-II Display Symptom description Range of Check Check condition
Codes
Front oxygen sensor heat- • 3 minutes have
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
Circuit Open more.
Front Oxygen Sensor Short Short circuit to • Intake air tem-
Circuit to Ground ground perature is 20 -
Front Oxygen Sensor Short 50 °C (68 -122
P0132 Short circuit to plus °F) Engine is running
Circuit to Battery
• Engine speed is
Front oxygen Sensor Cir-
P0133 Frequency too small approx. 2000 - Engine is running
cuit Slow Response
3000 r/min
Front Oxygen Sensor not Sensor not ready / • Vehicle is mov- Engine is running
Ready No signal ing at constant
P0134
Front Oxygen Sensor Sig-
nal Excursion Not Plausible
T
Signal excursion not
plausible / Signal er-
ror
speed on a
flat, level road
surface .
Engine is running
AF
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
R
for 30 seconds
(does not cross
0.6 V for 30
seconds).
D
• 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.
Dynamic Front Oxygen Sensor Ignition On ± 405.18 mv
Display Voltage Engine runs at idle 180 ~ 400

13A FUEL <IAFM+>

Actuator Front Oxygen Sensor Front Oxygen controller =
Idle speed
Test Heater ON
T
AF
R
D
DOIQC13AR11005

FUEL <IAFM+> 13A
REAR OXYGEN SENSOR WCH13ASHOOT11295
T
AF
R
D
DOIQC13AR11006
OPERATION

13A FUEL <IAFM+>

Codes tion
Downstream oxygen • 3 minutes have
Rear oxygen sensor heat-
P0036 sensor heater OBDI passed after en- Engine is running
er open circuit
diagnosis gine was started.
Downstream oxygen • Engine coolant
Rear oxygen sensor heat- temperature is
er short circuit to ground approx. 80 °C
diagnosis
(176 °F) or more.
Downstream oxygen
Rear oxygen sensor heat- • Idle position
er short circuit to battery switch:OFF
diagnosis
• The throttle posi-
Rear Oxygen Sensor Open tion sensor out-
Circuit put voltage is4.1
Rear Oxygen Sensor Short Short circuit to V or more.
Circuit to Ground ground • Open loop con-
Rear Oxygen Sensor Short trol in operation.
P0138 Short circuit to plus • 20 seconds have Engine is running
Circuit to Battery
Rear Oxygen Sensor passed after de-
P0139 Diag inhibited. celeration fin- Engine is running
T
Rich/Lean Switching Time
ished.
Downstream Oxygen Lambda sensor Heat- Set conditions :-
Sensor Open Circuit er fault • The oxygen
AF
Downstream Oxygen sensor (rear) out-
Rear Oxygen Sensor Sig-
P2270 Sensor rich voltage put voltage is 0.1 Engine is running
nal Stuck Lean
threshold check V or less.
Downstream Oxygen • The difference in
Rear Oxygen Sensor Sig- the maximum
P2271 Sensor lean voltage Engine is running
nal Stuck Rich and minimum
threshold check
R
values for the

oxygen sensor
(rear) output
voltage is 0.08 V
D
or less.
• The oxygen
Rear oxygen sensor signal Signal high during sensor (rear) out-
P2A01 put voltage is 0.5 Engine is running
high during fuel cut off fuel cut off
V or more.
• The above condi-
tions continue
for a continuous
period of 5
seconds.
Dynamic Dis- Ignition On ± 49974.7 mv
Rear Oxygen Sensor Voltage
play Engine runs at idle 180 ~ 401
Rear Oxygen controller
Actuator Test Rear Oxygen Sensor Heater Idling speed
= ON

FUEL <IAFM+> 13A
T
AF
R
DOIQC13AR11007
D

13A FUEL <IAFM+>
THROTTLE BODY ACTUATOR WCH13ASHOOT11296
T
AF
R
D
DOIQC13AR11008
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.

FUEL <IAFM+> 13A
Check condi-
tion
Throttle position sensor Load Sensor Failure or Engine is run-
P0068
/ Throttle body failure Throttle Failure ning
Engine is run-
ning
Fuel System Leak Detec- out of MAX
P0093
Engine is run-
max, Lambda out of
ning
MAX,
Engine is run-
ning
Fuel System Leak Detec- out of Min
P0094
Engine is run-
max, Lambda out of
ning
Min
failure ning
T
P0121 Throttle Failure • Excluding 60
Diagnostic ning
seconds after the
Voltage Throttle Posi- Engine is run-
P0122 position sensor 1 low ignition switch is
AF
tion Sensor 1 Low ning
turned to ON or
Voltage Throttle Posi- immediately after Engine is run-
tion Sensor 1 High the engine starts. ning
Voltage Throttle Posi- Set conditions: Engine is run-
tion Sensor 2 Low • When the idle ning
Voltage Throttle Posi- switch out is ON, Engine is run-
R
P0223 position sensor 2 high sensor output

tion Sensor 2 High ning
voltage is 2 V or
more for 4 Engine is run-
seconds. ning
D
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
error lower return Engine is run-
troller lower return
spring check ning
spring error
P1588
error upper return Engine is run-
troller upper return
spring check ning
spring error
P2100 open circuit
troller open circuit ning
P2101 short circuit
troller short circuit ning
lower position not Engine is run-
P2109 Lower position not
reached ning
Reached
Engine is run-
ning

13A FUEL <IAFM+>
Check condi-
tion
troller over heat protec-
tion
PWM exceeds Engine is run-
Throttle Actuator Con- threshold 1 ning
troller output position
monitoring PWM exceeds Engine is run-
threshold 2 ning
P2119
lower mec. stop adapt- Engine is run-
Throttle Actuator Con- ation outside range ning
troller Deviation exceed
Threshold control deviation ex- Engine is run-
ceeds threshold ning
Throttle/Pedal Ratio Engine is run-
check ning
Engine is run-
TPS1 plaus error
Throttle/Pedal Position ning
P2135
plausibility Engine is run-
TPS2 plaus error
T
TPS ratio error
ning
Engine is run-
ning
AF
upper position not Engine is run-
P2163 Upper Position not
reached ning
Reached
adaptation conditions Engine is run-
exceeded ning
Threshold
R

Engine is run-
ning
between Min, MAX
D

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
out of Max
P2281 of min in PL, Lambda
out of Min
min, Lambda out of
MAX

FUEL <IAFM+> 13A
Check condi-
tion
min, Lambda out of
Min
Engine is run-
Air Leak Between ning
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
T
(TPS)
Throttle body
TBA Adapta-
actuator adap- Idle speed Done
tion
AF
tion
Throttle body
DK Output
actuator out- Idle speed Performed
Stage
put stage
Emergency
Emergency TBA
Dynamic Display Adaptation throttle body
Idle speed OFF
R
actuator adapt-
Value
ation value
Sleep Mode Sleep mode
Idle speed OFF
Active active
D
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
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

13A FUEL <IAFM+>
T
AF
R
DOIQC13AR11009
D

FUEL <IAFM+> 13A
TMAP SENSOR (INTAKE AIR TEMPERATURE SENSOR AND VACUUM SENSOR)

WCH13ASHOOT11297
T
AF
R
DOIQC13AR11010
OPERATION INTAKE AIR TEMPERATURE SENSOR

D
The intake air temperature sensor, which is integrated with the Tmap sensor converts the engine intake
air temperature into a voltage and inputs it to the engine control unit, which then corrects the fuel
injection rate, etc., based on input signal.
The 5 power in the engine control unit is supplied via a resistor in the unit to the intake air temperature
sensor. Via the sensor which is a kind of resistor, it is then earthed in the engine control unit. The intake
air temperature sensor resistor has such characteristic that its resistance decreases as the intake air
temperature rises.
The intake air temperature sensor terminal voltage increases or decreases. Therefore, the intake air
temperature sensor terminal voltage changes with the intake air temperature, decreasing as the
temperature rises.
The vacuum sensor which is integrated in the Tmap sensor converts the air intake plenum pressure
to a voltage value and inputs it to the engine control unit. The engine control unit uses this signal
and the engine rpm to calculate the basic fuel injection timing.
5V of power is supplied to the vacuum sensor from the engine control unit, and the sensor circuit
earth is located in the engine control unit. The vacuum sensor output voltage is proportioned to the
air intake plenum pressure and sent to the engine control unit.

13A FUEL <IAFM+>
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).
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

of the boost sensor
AF
4 seconds. (This
correspond to the
absolute manifold
pressure of 4.9
kPa (0.7 psi, 1.48
in.Hg) or less).
R
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-
D
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.

FUEL <IAFM+> 13A

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
T
AF
R
D
DOIQC13AR11011

13A FUEL <IAFM+>
COOLANT TEMPERATURE SENSOR WCH13ASHOOT11298
T
AF
R
DOIQC13AR11012
OPERATION
The coolant temperature sensor converts the coolant temperature into a voltage and inputs it to the
D
engine control unit, which then control fuel injection rate and fast idle speed when the engine is cold,
based on the input signal.
The 5V power in the engine control unit is supplied via a resistor in the unit to the coolant temperature
sensor. Via the sensor which is a kind of resistor, it is then earthed in the engine control unit. The
coolant temperature sensor resistor has such characteristic that its resistance decreases as the coolant
temperature rises.
The coolant temperature sensor terminal voltage increases or decreases. Therefore, the coolant tem-
perature sensor terminal voltage changes with the coolant temperature, decreasing as the temperature
rises.

FUEL <IAFM+> 13A
Check condi-
tion
Coolant Temperature • Ignition switch: ON
Short circuit to Engine is run-
P0117 Sensor Short Circuit to • Excluding 60
ground ning
Ground seconds after the
Coolant Temperature Short circuit to Vbatt ignition switch is Engine is run-
P0118 turned to ON or
Sensor Open Circuit or Open circuit ning
immediately after
the engine starts.
Set conditions:
• Sensor output
voltage is 4.6 V or
more (correspond-
ing to an engine
coolant temperat-
ure of -45 °C (-49
°F) or less) for 4
seconds.
• Sensor output
voltage is 0.1 V or
T less for (corres-

ponding to an en-
gine coolant tem-
AF
perature of 140 °C
(284 °F) or more)
for 4 seconds.
Coolant Temperature Coolant temperature • Engine speed is ap- Engine is run-
P0119 prox. 500 r/min or
Signal Gradient Error signal gradient error ning
R
more.
Set conditions:
• The sensor output
voltage increases
D
from 1.6 V or less

(corresponding to
an engine coolant
temperature of 40
°C (104 °F) or
more) to 1.6 V or
more (correspond-
ing to an engine
coolant temperat-
ure of 40 °C (104
°F) or less)
• After this, the
sensor output
voltage is 1.6 V or
more for 5
minutes.

13A FUEL <IAFM+>

Engine temperature Engine runs at idle 89 °C (192.2 °F)
Dynamic Display Engine start temperat- 29 °C (84.2 °F) ( 0 °C (32 °F) ~
Engine runs at idle
ure 100 °C (212 °F))
T
AF
R
D
DOIQC13AR11013

FUEL <IAFM+> 13A
ACCELERATOR PEDAL SENSOR WCH13ASHOOT11299
T
AF
R
DOIQC13AR11014
OPERATION
The accelerator pedal sensor converts the changes (increase or decrease) of the depressed pedal into
D
pulse signal and inputs these signals to the engine control unit. The engine conrol unit determines
how much the changes of the depressed pedal.
5V power is supplied to the accelerator pedal sensor from the engine control unit, and the earth
connection is positioned to engine control unit.

13A FUEL <IAFM+>

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

FUEL <IAFM+> 13A
T
AF
R
DOIQC13AR11015
OXYGEN CONTROL WCH13ASHOOT11300

D
DOIQC13AR11016
OPERATION
The oxygen control which is integrated with oxygen sensor, works by detecting the concentration of
oxygen in exhaust gas; it converts those data to voltage, and inputs the resulting signals to the engine
control unit.

13A FUEL <IAFM+>
Fault codes PADT-II Display Symptom description Check condition

Maximum limit of lambda con- Maximum limit of lambda
Engine is running
0171
Maximum limit of adaptation Maximum limit of adaptation
Engine is running
Minimum limit of lambda con- Minimum limit of lambda
Engine is running
0172
Minimum limit of adaptation Minimum limit of adaptation
Engine is running
Ignition On 1
Oxygen control factor
Engine runs at idle 0.99 ~1.01
tion
Dynamic Display
Engine runs at idle ± 30
tion multiplicative value
tion fuel mass flow offset
T
AF
R
D

FUEL <IAFM+> 13A
T
AF
R
D
DOIQC13AR11017

13A FUEL <IAFM+>
INJECTORS WCH13ASHOOT11301
T
AF
R
D
DOIQC13AR11018
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.

FUEL <IAFM+> 13A
Fault
PADT-II Display Symptom description Range of Check Check Condition
Code
Injector Cir-
1
Injector Cir-
2
Injector Cir-
3
Injector Cir-
4 • Engine speed is ap-
Cylinder 1 Injector Injection valve dia- prox. 500-1000
P0261 short circuit to gnostic - short circuit r/min Engine is running
ground ground • The throttle posi-
Cylinder 1 Injector Injection valve dia- tion sensor output
P0262 short circuit to bat- gnostic - short circuit voltage is 1.15 V or Engine is running
tery
Cylinder 2 Injector
plus
T •
less
Actuator test by
PDT-2000 is not
AF
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.
R

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

13A FUEL <IAFM+>
T
AF
R
DOIQC13AR11019
D

FUEL <IAFM+> 13A
FUEL PUMP RELAY WCH13ASHOOT11302
T
AF
R
D
DOIQC13AR11020
OPERATION
The fuel pump is driven when the engine is cranking and running.

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

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

FUEL <IAFM+> 13A
T
AF
R
D
DOIQC13AR11021
MISFIRE WCH13ASHOOT11303
OPERATION
Commonly, misfire is due to the incompleteness of burning mixture between air and fuel. This problem
may be either due to the malfunction of ignition coil or spark plug or leakage of air flow to the engine.
Consequently, the compression between air and fuel by piston is not in optimum (2–18° BTDC-engine
idling or 2–45° BTDC-engine at 2500 r/min ). The incompleteness of burning mixture results carbon
monoxide, a pollutant gas which can pollute the environment.

13A FUEL <IAFM+>
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.
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
P0304 Misfire on cylinder 4 misfire (one of the
ted ning
coils fails).
cylinder 1
cylinder 2
Dynamic Display
cylinder 3
T Engine runs at idle 0 ~ 65535

AF
cylinder 4
potential
R
D

FUEL <IAFM+> 13A
T
AF
R
D
DOIQC13AR11022

13A FUEL <IAFM+>
KNOCK SENSOR WCH13ASHOOT11304
T
AF
R
DOIQC13AR11023
OPERATION
The detonation sensor converts cylinder block vibration caused by detonation into a voltage that is
D
proportional to intensity of vibration, and sends it to the engine control unit, which then provides
delay control of the ignition timing based on this signal.

FUEL <IAFM+> 13A
Check condi-
tion
Knock control system • Engine is run-
Ignition switch: ON
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
T of the crankshaft) is
less than 0.06 V for
200 times in succe-
AF
sion.
Dynamic Display Anti Knock Control Status Ignition On OFF / ON
R
D

13A FUEL <IAFM+>
T
AF
R
DOIQC13AR11024
D

FUEL <IAFM+> 13A
CRANKSHAFT SENSOR WCH13ASHOOT11305
T
AF
R
DOIQC13AR11025
OPERATION
The crankshaft sensor senses the crank angle (piston position) of each cylinder, converts it into a pulse
D
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

13A FUEL <IAFM+>
Check condi-
tion
crankshaft sensor failure crankshaft sensor fail-
Engine is run-
P0335 open or short circuit ure open or short
ning
diagnosis CRK_OC circuit
crankshaft signal miss- • Engine is running Engine is run-
crankshaft signal missing
ing Set conditions: ning
crankshaft signal im- crankshaft signal im- • Sensor output Engine is run-
plausible plausible voltage does not ning
crankshaft loss of syn- crankshaft synchroniz- change for 4 Engine is run-
P0336 seconds (no pulse
chronization diagnosis ation lost ning
crankshaft tooth num- wrong crankshaft signal input) Engine is run-
ber error diagnosis tooth number ning
crankshaft tooth period crankshaft tooth peri- Engine is run-
diagnosis od out of range ning
Function PADT-II Display Full name Check condition Standard value
Dynamic Dis- Target Wheel Adapt- Target Wheel Adapt- Idle speed (Engine runs
Performed
play ation ation for 5 minutes)
TROUBLESHOOTING PROSEDURE
T
AF
R
D
DOIQC13AR11026

FUEL <IAFM+> 13A
IGNITION COIL WCH13ASHOOT11306
T
AF
R
D
DOIQC13AR11027
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.

13A FUEL <IAFM+>
Check condi-
tion
P0351
cuit ning
P0352
cuit ning
Open circuit
P0353
cuit ning
P0354 • Engine speed is ap-
cuit ning
prox. 500-4000
Ignition Coil 1 short cir- r/min . Engine is run-
cuit to ground • Engine is not ning
Ignition Coil 1 short cir- cranking. Engine is run-
cuit to battery Set conditions: ning
Ignition Coil 3 short cir- • The crank angle Engine is run-
P2303 Short circuit to ground sensor detects an
cuit to ground ning
Ignition Coil 3 short cir- abnormal engine Engine is run-
P2304 Short circuit to plus speed caused by
T
misfire (one of the
Ignition Coil 4 short cir- coils fails). Engine is run-
cuit to ground ning
AF
cuit to ground ning
R

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
D

FUEL <IAFM+> 13A
T
AF
R
DOIQC13AR11028
CATALYTIC SYSTEM WCH13ASHOOT11307

D
DOIQC13AR11029
OPERATION
Catalytic converter is designed specifically to reduce the pollution air due to the pollutant gases (i. e.
carbon monoxide), resulted from the burning mixture of air and fuel. It removes the gases from the
engine to ensure that the burning mixture of air and fuel are in optimum condition. Basically, the
catalytic converter system consists of primary catalytic converter and secondary catalytic converter.
The primary catalytic converter ensures that all the gases are removed from the engine while the
secondary catalytic converter checks whether the gases is totally removed.

13A FUEL <IAFM+>
Fault Symptom Descrip-

PADT-II Display Range of Check Check Condition
Codes tion
• Engine speed is
approx.
500-4000 r/min
Catalyst system effi- .
0420 ciency below Catalyst efficiency • Engine stumbles Engine is running
threshold when the cata-
lytic converter
connector is
plugged out.
Catalyst temperat-
Dynamic Display Engine runs at idle 50 ~ 950 °C (122 ~ 1742 °F)
ure model
T
AF
R
D
DOIQC13AR11030

FUEL <IAFM+> 13A
CANNISTER PURGE SOLENOID VALVE WCH13ASHOOT11308
T
AF
R
D
DOIQC13AR11031
OPERATION
The cannister purge solenoid valve is an ON-OFF type of one which controls introduction of purge air
from the cannister into the intake air plenum.
The battery power is supplied to the cannister purge solenoid valve through main relay. When the
cannister purge solenoid valve turns ON the power transistor in the unit, current flows to the coil,
introduction purge air.

13A FUEL <IAFM+>
Check Ccondi-
tion
Present electrical Can- • Engine is checking
Cannister purge solen- nister purge solenoid Set conditions Engine is run-
P0444
oid valve Open Circuit valve failure open cir- (when engine is ning
cuit cold): 40 °C (104
Present electrical can- °F) or less.
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
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) .
Dynamic Display Purge Duty Cycle
T Ign on
Engine runs at idle
0.00 %
0.04 %
AF
Purge Duty Cycle = X %
(X value increase from
0~100%)
Actuator Test Purge valve Ignition On
be heard when solenoid
R
valve is driven
D

FUEL <IAFM+> 13A
T
AF
R
DOIQC13AR11032
D

13A FUEL <IAFM+>
ENGINE FAN WCH13ASHOOT11309
T
AF
R
D
DOIQC13AR11033
OPERATION
The power transistor inside the engine-ECU turns the fan motor relay on and off.
When the engine control unit turns the power transistor ON, it supplies the power to the radiator
fan relays. This causes the relay to turn ON, and current is supplied from the ignition switch via these
relays to drive the motor which are connected to them.

FUEL <IAFM+> 13A
Check condi-
tion
Engine is run-
P0480 Fan 1 Open circuit Open circuit Set conditions: ning and A/C
• Engine and A/C switch is On
switch must be ON Engine is run-
Fan 1 Short circuit To
P0691 Short circuit to ground first. ning and A/C
ground
• The fan motor switch is On
should be heard to Engine is run-
Fan 1 Short circuit To operate.
P0692 Short circuit to battery ning and A/C
Battery
switch is On
Actuator Test Fan 1 Ignition ON be heard when purge
valve is driven
T
AF
R
D
DOIQC13AR11034

13A FUEL <IAFM+>
VEHICLE SPEED SIGNAL [ A/T ] WCH13ASHOOT11310
T
AF
R
D
DOIQC13AR11035
OPERATION
The vehicle speed is generated by the wheel speed sensor which is located at the vehicle’s wheel. It
calculates the vehicle speed based upon the rotating speed of the vehicle’s wheel via magnetic field..
The vehicle speed signal to meter combination, ECU and TCU via CAN bus.

FUEL <IAFM+> 13A
Symptom descrip-
tion
ON.
• Excluding 60
seconds after
the ignition is
turned to ON
or immediately
after the en-
gine starts.
• Idle switch:
OFF.
• Engine speed is
Not Valid
• Driving under
high engine
load condi-
tions. Set condi-
T tions:
• Sensor output
voltage does
AF
not change for
4 seconds (no
pulse signal in-
put).
Dynamic Display Vehicle Speed Ignition ON 0 km/h (0 mph)
R
D

13A FUEL <IAFM+>
T
AF
R
D
DOIQC13AR11036

FUEL <IAFM+> 13A
VEHICLE SPEED SIGNAL [ M/T ] WCH13ASHOOT11311
T
AF
R
D
DOIQC13AR11037
OPERATION
The vehicle speed is generated by the speed sensor.It send’s the signal to meter combination.
The meter combination convert the vehicle speed signal to CAN for after controler usage.

13A FUEL <IAFM+>
Symptom descrip-
tion
ON.
• Excluding 60
seconds after
the ignition is
turned to ON
or immediately
after the en-
gine starts.
• Idle switch:
OFF.
• Engine speed is
Not Valid
• Driving under
high engine
load condi-
tions. Set condi-
T tions:
• Sensor output
voltage does
AF
not change for
4 seconds (no
pulse signal in-
put).
Dynamic Display Vehicle Speed Ignition ON 0 km/h (0 mph)
R
D

FUEL <IAFM+> 13A
T
AF
R
D
DOIQC13AR11038

13A FUEL <IAFM+>
BRAKE LIGHT SWITCH (Stop lamp switch) WCH13ASHOOT11312
T
AF
R
D
DOIQC13AR11039

FUEL <IAFM+> 13A
OPERATION
The brake light switch operates when the pedal is pressed. It signals the brake lamp to ON once the
pedal brake is pressed. The power from battery is supplied to the brake light switch and is connected
to the ECU-engine control unit.
Check condi-
tion
Set conditions:
• Pedal brake
pressed-brake light
Engine is run-
P0504 Brake Switch Error plausibility ON.
ning
• Pedal brake re-
leased-brake light
OFF.
T
AF
R
D
DOIQC13AR11040

13A FUEL <IAFM+>
ENGINE SPEED SIGNAL [ A/T ] WCH13ASHOOT11313
T
AF
R
D
DOIQC13AR11041
OPERATION
The engine speed sensor which is located between ignition system and speedometer converts the
engine speed into a pulse and inputs it to the meter combination, which then provides the idle speed
control, etc.based on this signal.
The engine speed sensor generates the engine speed signal by repeatedly opening and closing between
the voltage of about 12V applied from the ignition system to meter combination.

FUEL <IAFM+> 13A
Symptom descrip-
tion
• 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
high engine
load condi-
tions. Set condi-
T tions:
• Sensor output
voltage does
AF
not change for
4 seconds (no
pulse signal in-
put).
R
Dynamic Display Engine speed

D

13A FUEL <IAFM+>
T
AF
R
DOIQC13AR11042
D

FUEL <IAFM+> 13A
ENGINE SPEED SIGNAL [ M/T ] WCH13ASHOOT11314
T
AF
R
D
DOIQC13AR11043
OPERATION
The engine speed is generated by the pulse generator which is located at the manual Transmission
Assembly. It calculates the engine speed based upon the manual Transmission speed.
The engine speed signal is generated by repeatedly opening and closing between the voltage of about
5V applied from the engine control unit-ECU and earth.

13A FUEL <IAFM+>
Symptom descrip-
tion
• 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
high engine
load condi-
tions. Set condi-
T tions:
• Sensor output
voltage does
AF
not change for
4 seconds (no
pulse signal in-
put).
R
Dynamic Display Engine speed

D

FUEL <IAFM+> 13A
T
AF
R
DOIQC13AR11044
D

13A FUEL <IAFM+>
IMMOBILISER WCH13ASHOOT11315
T
AF
R
D
DOIQC13AR11045
OPERATION
Immobiliser is designed to provide protection from automobile thefts. This system is equipped with
a software to lock the engine control unit. The engine control unit can only operate if the touch key
is placed at the touch key receiver which is integrated with key ring antenna. Once the touch key is
contacted with touch key receiver, and the right code is sent to the ECU which enables the engine to
start.
Check condi-
tion
immobilizer failure
P0513 Immobilizer Locked due to wrong authen- Ignition On
• Check the key ring
tication process
connection with
immobilizer failure engine ECU
Communication with
P0633 due to no communica- Ignition On
Transponder Missing
tion with transponder

FUEL <IAFM+> 13A
T
AF
R
DOIQC13AR11046
D

13A FUEL <IAFM+>
POWER SUPPLY WCH13ASHOOT11316
T
AF
R
D
DOIQC13AR11047

FUEL <IAFM+> 13A
OPERATION
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
T
AF
R
D
DOIQC13AR11048

13A FUEL <IAFM+>
ENGINE CONTROL UNIT WCH13ASHOOT11317
DOIQC13AR11049
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 power supply from battery must be checked whether it is properly connected.
Fault codes PADT-II Display
T
Symptom description Range of check
Check condi-
tion
AF
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-
R
ECU Internal Fault - Pro- connecting the

P060C GENERAL Ignition ON
cessor monitoring terminal battery.
D

FUEL <IAFM+> 13A
T
AF
R
DOIQC13AR11050
D

13A FUEL <IAFM+>
STARTER CONTROL WCH13ASHOOT11318
T
AF
R
D
DOIQC13AR11051
OPERATION
The starter control is driven when the engine is cranking and while the engine is running.

FUEL <IAFM+> 13A
When the engine is cranking or running, the engine control unit turns the power transistor ON, which
supplies the power to the starter relay. This causes the starter relay to turn ON and current is supplied
from the ignition switch via the starter relay to drive the starter motor.
Fault codes PADT-II Display Symptom description Range of Check Check condition
Starter Relay Open Cir-
P0615 Open circuit • Engine must be Ignition ON
cuit
ON first.
Starter Relay Short Cir- Short circuit to
P0616 • The starter motor Ignition ON
cuit to Ground ground
should be heard
Starter Relay Short Cir- Short circuit to bat- to operate.
P0617 Ignition ON
cuit to Battery tery
T
AF
R
D
DOIQC13AR11052

13A FUEL <IAFM+>
SENSOR SUPPLY WCH13ASHOOT11319
T
AF
R
D
DOIQC13AR11053
OPERATION
Engine ECU check to throttle position sensor, pedal voltage sensor, TMAP sensor and Camshaft sensor
power voltage for abnormal.

FUEL <IAFM+> 13A
Check condi-
tion
Sensor reference voltage less than 4.4 V
P0642
‘A’ circuit LOW • Pedal voltage sensor
1 power voltage less
than4.4 V
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
voltage less than 4.4 V
P0652 • Camshaft sensor
‘B’ circuit LOW
power voltage less
than4.4 V
P0653
T
voltage more than
5.59 V
AF
‘B’ circuit HIGH • Camshaft sensor
power voltage more
than5.59 V
R
D
DOIQC13AR11054

13A FUEL <IAFM+>
AIR COND CLUTCH WCH13ASHOOT11320
T
AF
R
D
DOIQC13AR11055
OPERATION

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

OFF
Dynamic Display Air cond request signal Ignition ON
ON
T
AF
R
D

13A FUEL <IAFM+>
T
AF
R
DOIQC13AR11056
D

FUEL <IAFM+> 13A
VIM (VACCUM ACTUATOR) [IAFM] WCH13ASHOOT11321
T
AF
R
D
DOIQC13AR11057
OPERATION
The Vacuum actuator control the intake of air in the VIM module. It controls the air flow in the intake
manifold either to short-runner or long-runner during certain engine rpm to increase the driveability
performance.
Function of Va- Intake manifold Intake manifold

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

13A FUEL <IAFM+>
Check condi-
Fault codes PADT-II Display Symptom description
tion
P0660 VIM Actuator Electrical Power Engine run-
VIM Actuator open circuit
Stage Diagnosis ning and en-
VIM Actuator Electrical Power VIM Actuator short circuit to gine temperat-
P0661 ure must
Stage Diagnosis ground
above 60 °C
VIM Actuator Electrical Power (140 °F), and
P0662 VIM Actuator short circuit to plus engine run at
Stage Diagnosis
4,500 rpm .
Camshaft Control Active Engine running and Active
Intake Manifold Control engine temperature
Active
Dynamic Display Active must above 60 °C
Diagnostic Distance (140 °F), and engine
run at 4,500 rpm. KM_MIL
Counter Since MIL On
T
AF
R
D
DOIQC13AR11058

FUEL <IAFM+> 13A
MAIN RELAY WCH13ASHOOT11322
T
AF
R
D
DOIQC13AR11059

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

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

FUEL <IAFM+> 13A
T
AF
R
D
DOIQC13AR11060

13A FUEL <IAFM+>
TRANSMISSION CONTROL UNIT (CVT) WCH13ASHOOT11323
DOIQC13AR11061
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.
T
Symptom descrip-
AF
tion
One of the follow-
ing causes may be
suspected:
• No power
supply to
R
CVT.
• Defective of
Transmission control unit Transmission limp transmission
limp home diagnosis home unit -CVT.
D
• CAN bus is off

• CAN ECU
communica-
tion failed
• CAN engine
torque signal
error
Dynamic Display Gear Lever Position Ignition ON D / P/N

FUEL <IAFM+> 13A
T
AF
R
DOIQC13AR11062
D

13A FUEL <IAFM+>
P/N SWITCH WCH13ASHOOT11324
T
AF
R
DOIQC13AR11063
OPERATION
1. For security, the shift lever position must be in either P or N position in order for the engine can
D
be started.
2. CVT - TCU sends the shift lever position to engine ECU via CAN . A back-up signal is send via
hardwire (pin no 92) from CVT-TCU to engine ECU
3. Engine ECU to set an error when it detects differences between CAN signal and the hardwire
signal.
Check condi-
tion
• Ignition switch ON
position
P0850 P/N switch Plausibility Plausible Value Ignition ON
• Can voltage measure-
ment 0~3 V
Dynamic Display Gear position Ignition ON D, P/N

FUEL <IAFM+> 13A
T
AF
R
DOIQC13AR11064
D

13A FUEL <IAFM+>
PEDAL/BRAKE SWITCH WCH13ASHOOT11325
T
AF
R
D
DOIQC13AR11065

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

13A FUEL <IAFM+>
T
AF
R
D
DOIMC13AR11102

FUEL <IAFM+> 13A
CAN COMUNICATION WCH13ASHOOT11326
T
AF
R
D
DOIQC13AR11067
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.

13A FUEL <IAFM+>
Fault
PADT-II Display Symptom description Range check Check condition
codes
CAN Diagnosis -
U0073 CAN bus off Engine is running
Buss Off
communicating on
with ECU
the CAN-HS bus
CAN Diagnosis - Lost • Check the wiring
U0101 Communication harness between Engine is running
communicating on
with TCU ECU connector
the CAN-HS bus
and TCU connect-
Error in the respect- or.
communicating on
with ABS/ESP
the CAN-HS bus
communicating on
T
with meter cluster
the CAN-HS bus
AF
R
D
DOIQC13AR11068

FUEL <IAFM+> 13A
TROUBLE SYMPTOM WCH13ASHOOT11327

Inspection
No.
Communication with all
1 13A/126
systems is not possible
Communication with PADT-II is
impossible Communication with en-
gine-ECU only is not pos- 2 13A/126
sible
does not illuminate right
after the ignition switch 3 13A/127
Engine warning lamp and related is turned to the ON posi-
parts tion
remains illuminating and 4 13A/128
never goes out
T
No initial combustion
5 13A/129
AF
Initial combustion but no
Starting complete combustion 6 13A/130
Takes too long time to
7 13A/131
start (improper starting)
Unstable idling (Rough
8 13A/132
R
Idling, hunting )
Idling speed is high (Im-
Idling stability (Improper idling) 9 13A/133
Idling speed is low (Im-
D
10 13A/134
When the engine is cold,
11 13A/135
it stalls at idling (Die out)
When the engine be-
comes hot, it stalls at id- 12 13A/136
Idling stability (Engine stalls) ling (Die out)
13 13A/137
starting the car (Pass out)
14 13A/138
decelerating

13A FUEL <IAFM+>
Inspection
No.
Hesitation, sag or stumble 15 13A/139
vibration when accelerat- 16 13A/140
ing
Driving vibration when decelerat- 17 13A/141
ing
Poor acceleration 18 13A/142
Surge 19 13A/143
Knocking 20 13A/144
Dieseling 21 13A/145
Too high CO and HC concentration when idling 22 13A/145
Low alternator output voltage (approx. 12.3 V ) 23 13A/146
Power supply system and ignition switch-IG system 24 13A/147
T
Fuel pump system 25 13A/148
Ignition switch-ST system <M/T> 26 13A/149
Ignition switch-ST and inhibitor switch system <A/T> 27 13A/150
AF
A/C switch and A/C relay system 28 13A/151
Fan motor relay system (Radiator fan, A/C condenser fan) 29 13A/152
Tank purge valve system 30 13A/153
PADT-II: Inspection of no initial combustion 31 13A/154
Ignition system: Inspection of no initial combustion 32 13A/155
R
PADT-II: Check if incomplete combustion occurs 33 13A/156

Check if hunting occurs 34 13A/157
PADT-II: Check if idling speed is unstable 35 13A/158
D
PADT-II: Engine stalling inspection when the engine is

36 13A/159
warmed up and idling
PADT-II: Check if hesitation, sag, stumble or poor accelera-
37 13A/160
tion occurs
PADT-II: Check if surge occurs 38 13A/161
Check the engine-ECU power supply and earth circuit 39 13A/162
Check fuel pump circuit 40 13A/163
Check fuel pump drive control circuit 41 13A/164
Check throttle body actuator (TBA) output circuit 42 13A/165
Check injector control circuit 43 13A/166
Check ignition coil and power transistor unit circuit 44 13A/167

FUEL <IAFM+> 13A
PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) WCH13ASHOOT11328
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)
T
pressed or while it is being used.
“Hesitation” is the delay in response of the vehicle
AF
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
R
Driving maximum speed.

Engine speed increase is delayed when the accelerator
Stumble
pedal is initially depressed for accelerated.
D
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”.

13A FUEL <IAFM+>
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS WCH13ASHOOT11329
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 )
wire.
T
AF
R
D
DOIQC13AR11069
PADT-II Communication with engine-ECU is impossible

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

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11070
R
The engine warning lamp does not illuminate right after the ignition switch is turned to the ON
position
D
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.

13A FUEL <IAFM+>
T
AF
DOIQC13AR11071
R
The engine warning lamp remains illuminating and never goes out.
D
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.

FUEL <IAFM+> 13A
T
AF
R
D
DOIQC13AR11072
No initial combustion (starting impossible)

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

13A FUEL <IAFM+>
T
AF
DOIQC13AR11073
R
Initial combustion but no complete combustion (starting impossible)

D
Initial combustion but no complete combustion (starting Probable cause

impossible)
• Malfunction of the ignition sys-
tem.
• Malfunction of the injectors sys-
In such cases as the above, the cause is probably that the spark tem.
plugs are generating sparks but the sparks are weak, or the • Malfunction of the throttle body
initial mixture for starting is not appropriate. actuator system.
• Foreign materials in fuel.

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11074
R
Takes too long time to start (Incorrect Starting)

D
Takes too long time to start (Incorrect Starting) Probable cause

that the spark is weak and ignition is difficult, • Malfunction of the injectors system.
the initial mixture for starting is not appropriate, • Inappropriate gasoline use.
or sufficient compression pressure is not being • Poor compression.
obtained.

13A FUEL <IAFM+>
T
AF
DOIQC13AR11075
R
Unstable idling (Rough idling, hunting)

D
Unstable idling (Rough idling, hunting) Probable cause

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

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11076
R
Idling speed is high (Improper idling speed)

D
Idling speed is high (Improper idling speed) Probable causes

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

13A FUEL <IAFM+>
T
AF
DOIQC13AR11077
R
Idling speed is low (Improper idling speed )

D
Idling speed is low (Improper idling speed) Probable cause

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

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11078
R
When the engine is cold, it stalls at idling (Die out)

D
When the engine is cold, it stalls at idling (Die

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

13A FUEL <IAFM+>
T
AF
R
D
DOIQC13AR11079
When the engine is hot, it stalls at idling (Die out)

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

FUEL <IAFM+> 13A
T
AF
R
D
DOIQC13AR11080
The engine stalls when starting the car (Pass out)

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

13A FUEL <IAFM+>
T
AF
DOIQC13AR11081
The engine stalls when decelerating

R
The engine stalls when decelerating Probable cause

that the intake air volume is insufficient due to • Malfunction of the throttle body actuator.
D
the defective of throttle body actuator.

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11082
R
Hesitation, sag or stumble

D
Hesitation, sag or stumble Probable cause

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

13A FUEL <IAFM+>
T
AF
DOIQC13AR11083
R
The feeling of impact or vibration when accelerating

D
The feeling of impact or vibration when

Probable cause
accelerating
that there is an ignition leak accompanying the • Malfunction of the ignition system.
increase in the spark plug demand during accel-
eration.

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11084
The feeling of impact of vibration when decelerating

R
The feeling of impact of vibration when

Probable cause
decelerating
D
Malfunction of the throttle body actuator sys- • Malfunction of the throttle body actuator system.
tem is suspected.

13A FUEL <IAFM+>
T
AF
DOIQC13AR11085
R
Poor acceleration
D
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.

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11086
R
Surge
D
Surge Probable cause

Defective ignition system, abnormal air-fuel ratio, etc. • Malfunction of air-fuel ratio control sys-
are suspected. tem.
• Injectors do not work.

13A FUEL <IAFM+>
T
AF
DOIQC13AR11087
R
Knocking
D
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

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11088
Dieseling
R
Dieseling Probable cause

Fuel leakage from injectors is suspected. • Fuel leakage from injectors.
D
DOIQC13AR11089
Too high CO and HC concentration when idling

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

13A FUEL <IAFM+>
T
AF
R
D
DOIQC13AR11090
Low Alternator Output Voltage (Approx 12.3 V )

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

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11091
R
Power supply system and ignition switch-IG system

D
Power supply system and ignition switch-IG system Probable cause

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

13A FUEL <IAFM+>
T
AF
DOIQC13AR11092
R
Fuel pump system

D
Fuel pump system Probable cause

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

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11093
R
Ignition switch-ST system [M/T]

D
Ignition switch-ST system [M/T] Probable cause

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

13A FUEL <IAFM+>
T
AF
DOIQC13AR11094
R
Ignition switch-ST and inhibitor switch system [CVT]

D
Ignition switch-ST and inhibitor switch system [CVT] Probable cause

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

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11095
R
A/C switch and A/C relay system

D
A/C switch and A/C relay system Probable cause

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

13A FUEL <IAFM+>
T
AF
DOIQC13AR11096
R
Fan motor relay system (Radiator fan)

D
Fan motor relay system (Radiator fan) Probable cause

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

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11097
R
Tank purge valve system

D
Tank purge valve system Probable cause

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

13A FUEL <IAFM+>
T
AF
DOIQC13AR11098
R
PADT-II: Inspection of no initial combustion

D

• Malfunction of camshaft sensor
In such cases above, the the cause is probably malfunc- • Malfunction of crank angle sensor
tion of sensors and actuators as per next table • Malfunction of fuel pump system
• Malfunction of coolant temperature sensor

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11099
R
Ignition system: Inspection of no initial combustion

D

The cumbustion is initiate by the ignition system, where signal • Malfunction of ignition system
is sent to engine ECU and the ECU turns the injectors and ignition • Malfunction of crank angle sensor
coil . • Malfunction of engine ECU

13A FUEL <IAFM+>
T
AF
DOIQC13AR11100
R
PADT-II: Check if incomplete combustion occurs

D
In complete combustion occurs Probable cause

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

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11101
R
Check if hunting occurs

D
Hunting occurs Probable cause

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

13A FUEL <IAFM+>
T
AF
DOIQC13AR11102
R
PADT-II: Check if idling speed is unstable

D
Idling speed is unstable Probable cause

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

FUEL <IAFM+> 13A
T
AF
R
D
DOIQC13AR11103
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

13A FUEL <IAFM+>
T
AF
R
D
DOIQC13AR11104
PADT-II: Check if hesitation, sug, stumble or poor acceleration occurs

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

FUEL <IAFM+> 13A
T
AF
R
D
DOIQC13AR11105
PADT-II: Check if surge occurs

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

13A FUEL <IAFM+>
T
AF
R
D
DOIQC13AR11106
Check the engine-ECU power supply and earth circuit

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

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11107
R
Check fuel pump motor circuit

D
Check fuel pump motor circuit Probable cause

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

13A FUEL <IAFM+>
T
AF
DOIQC13AR11108
Check the fuel pump relay drive circuit

R
Check the fuel pump relay drive circuit Probable cause

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

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11109
R
Check throttle body actuator (TBA) output circuit

D
Check throttle body actuator (TBA) output

Probable cause
circuit
In such cases, the cause is probably as listed • Throttle body actuator harness open circuit/ short cir-
in the next column cuit

13A FUEL <IAFM+>
T
AF
DOIQC13AR11110
R
Check injector control circuit

D
Check injector control circuit Probable cause

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

FUEL <IAFM+> 13A
T
AF
DOIQC13AR11111
R
Check ignition coil and power transistor unit circuit

D
Check ignition coil circuit Probable cause

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

13A FUEL <IAFM+>
/ 168 DATA LIST
T
AF
DOIQC13AR11112
R
DATA LIST WCH13ASHOOT11373

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

FUEL <IAFM+> 13A
DATA LIST / 169
In a new vehicle [driven approximately 500 km (310.68 mile) or less], the step of the stepper
motor is sometimes 30 steps greater than the standard value.
CURR PADT– II DISPLAY CHECK CONDI- STANDARD

UNIT REMARKS
NAME TION VALUE
89~92 °C
Engine temperat-
1 Ign on (192.2~197.6 °C Engine coolant temperature
ure
°F)
Engine start tem- 20~100 °C
2 Ign on °C Initial starting temperature
perature (68~212 °F)
Intake air temper- 33~100 °C
3 Ign on °C Temperature at intake manifold
ature (91.4~212 °F)
Engine run at
±850 rpm
idle, a/c off
4 Engine speed rpm Engine speed at idle
Engine run at
±850 rpm
idle, a/c on
Idle speed set-
5 Ign on 850 rpm rpm Idle speed set-piont value
point
Engine run at
T
6 Engine load 0.26 ~ 0.31 — Engine load
idle
Ign on 1010 hpa
Intake manifold
7 Engine runs at hPa Pressure at intake manifold
AF
pressure 410 hpa
idle
Ign on 8.63 %
Throttle body posi-
8 Engine runs at % TPS Throttle position
tion sensor (tps) 4.31 %
idle
Ign on ~ 0 °crk
R
9 Ignition timing Engine runs at °CRK Ignition timing degree crank

~ 9.2 °crk
idle
Ign on 0 ms
D
10 Injection time Engine runs at ms Injection timing

4.3 ~ 4.43 ms
idle
Ign on 11.6 ~ 12.0 V
11 Battery voltage Engine runs at V Battery voltage
13.5 V
idle
Ign on 0.00 %
12 Purge duty cycle Engine runs at % Percentage purge opening
0.04 %
idle
0 km/h (0
13 Vehicle speed Ign on km/h Value increases as vehicle moves
mph)
Ign on 1
Oxygen control
14 Engine runs at — Oxygen control factor
factor 0.99 ~1.01
idle
Ign on 0 ~ 900 mv
Front oxygen
15 Engine runs at mV Voltage oxygen sensor
sensor voltage 180 ~ 400 mv
idle

13A FUEL <IAFM+>
/ 170 DATA LIST

UNIT REMARKS
NAME TION VALUE
Ign on 0 ~ 900 mv
Rear oxygen sensor
16 Engine runs at mV Voltage oxygen sensor
voltage 180~401 mv
idle
Oxygen long term Engine runs at
17 ± 30 % Fuel adaptation
adaptation idle
Oxygen long term
Engine runs at
18 adaptation multi- ± 30 % Fuel adaptation
idle
plicative value
Oxygen long term
Engine runs at
19 adaptation fuel ± 30 % Fuel adaptation
idle
mass flow offset
50 ~ 950 °C
Catalyst temperat- Engine runs at
20 (122 ~ 1742 °C Catalyst temperature
ure model idle
°F)
Catalyst damaging Engine runs at
21 0 ~ 65535 — Misfire detection counter - cylinder 1
misfire cylinder 1 idle
22
0 ~ 65535 —
T Misfire detection counter - cylinder 2

AF
25 0 ~ 65535 — —
misfire potential idle
± 30.0± ± ± ±
R
kgm (NaN±
Idle torque loss ad- Engine runs at NaN± NaN
26 Nm Torque losst adaptation
aptation value idle Nm, NaN±
D
NaN± NaN
ft.lbs)
Accelerator pedal
27 Ign on 0.00 % Varies when aps pressed
position
Distance since mil
28 Ign on 0 km Check fault code if value > 0km
on
Engine runs at Not active / Idle state status; active when idle
44 Idle state —
idle active switch is on
Engine runs at Not active / Load status; active when accelerator
45 Full load request —
idle active pedal at full throttle
Gear position; d hwen gear position
46 Gear position Ign on D, p/n — set to drive, p/n when gear shift to
parking/neutral
Air cond request Engine runs at Air conditioner status; on when air
47 Off / on —
signal idle cond switch to on
Engine runs at
48 Camshaft control Off / on — VVT controller status
idle
Intake manifold Engine runs at
49 Off / on — VIM controller status
control idle

FUEL <IAFM+> 13A
ACTUATOR TEST / 171

UNIT REMARKS
NAME TION VALUE
Anti knock control Engine runs at
50 Off / on — Knock control status
status idle
Engine runs at
51 Fuel cut off (SAS) Off / on — Fuel cut off condition
idle
Throttle body ad- Engine runs at In progress / Throttle body adaptation status; done
52 —
aptation (TBA) idle done when tba adaptation is completed
Cruise control cancel switch status;
Cruise control - Engine runs at Not active /
53 — active when cruise cancel switch is
cancel switch idle active
cancelled
Cruise control switch status; active
Cruise control set Engine runs at Not active /
54 — when cruise control switch is set to
deceleration idle active
decelerate
Cruise control switch status; active
Cruise control set Engine runs at Not active /
55 — when cruise control switch is set to
acceleration idle active
accelerate
Clutch actuated Engine runs at Not active /
56 — —
T
(m/t) idle active
Cruise control oper- Engine runs at Cruise control operation status; on
57 Off / on —
ation idle when auto cruise in operating mode
AF
Target wheel ad- Engine runs at In progress /
58 — —
aptation idle done
ACTUATOR TEST WCH13ASHOOT11374
ACTUATOR TEST REFERENCE TABLE

R
Item Inspection Inspection Normal Inspection pro-

Drive contents
No. item contents condition cedure No.
Front Oxy- Actuate the Front Oxy-
Check status
D
1 gen Sensor Lambda probe Idling speed gen control- 13A/38

on PADT-II
Heater heater 1 to ON ler = ON
Rear Oxygen Actuate the Rear Oxy-
Check status
2 Sensor Heat- Lambda probe Idling speed gen control- 13A/41
on PADT-II
er heater 2 to ON ler = ON
Throttle Po-
sition Sig-
Check status nal = X %
Throttle valve • Warmed up on PADT-II (X value in-
actuate to the Engine for crease from
Throttle 0~100%)
3 1. 0% few minutes 13A/44
valve
2. 50% • Set Engine at RPM goes
3. 100% idling speed higher
Listen for en-
from idle
gine sound
speed set-
ting

13A FUEL <IAFM+>
/ 172 ACTUATOR TEST
Item Inspection Inspection Normal Inspection pro-

Drive contents
No. item contents condition cedure No.
Cut fuel to No.
4 Injector 1
1 injector Idling condi-
Injector 2 Cut fuel to No. • Warmed up
5 tion be-
2 injector the Engine for Check cylin-
comes dif-
few minutes ders which af- 13A/60
Injector 3 Cut fuel to No. ferent (be-
6 • Set Engine at fect idling
3 injector comes un-
idling speed
Injector 4 Cut fuel to No. stable)
7
4 injector
Pinch the re-
• Ignition turn hose with
switch: ONfingers to feel
• Fuel pump Pulse is felt
the pulse of
Fuel pump oper- Forced driv-
the being recir-
8 Fuel pump ates and fuel is ing Inspect
culated. 13A/63
recirculated. according
Listen for the
to both the Sound of
sound of fuel
above condi- operation
pump opera-
tions
T
tion.
is heard
Purge Duty
AF
Cycle = X %
Check status
(X value in-
on PADT-II
crease from
0~100%)
Purge valve Sound of
Ignition switch:
9 Purge valve turns from OFF operation 13A/77
ON
to ON Listen for can be
R
purge valve heard

operation when
sound solenoid
D
valve is
driven
Sound of
operation
Listen for fan can be
Drive the fan Ignition switch:
10 Fan 1 motor opera- heard 13A/80
motor (radiator) ON
tion sound when
purge valve
is driven

FUEL <IAFM+> 13A
CHECK AT THE ENGINE-ECU WCH13ASHOOT11375
DOIQC13AR11113

1. Connect a needle-nosed wire probe (test harness: MB991223 or paper clip) to a voltmeter probe.
2. Insert the neddle-nosed wire probe into each of the engine-ECU connector terminals from the
side, and measure the voltage while referring to the check chart.
NOTE
T
(1) Make the voltage measurement with the engine-ECU connected.
(2) You may find it convenient to pull out the engine-ECU to make it easier to reach connector ter-
AF
minals.
(3) The checks can be carried out off the order given in the chart.
CAUTION
vehicle wiring, the sensor, engine-ECU or all of them. Be careful to prevent this!
R
Symbol Description
A ECU harness
3. If voltmeter shows any division from standard value, check the corresponding sensor, actuator
D
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.
DOIQC13AR11114
ENGINE-ECU CONNECTOR TERMINAL ARRANGEMENT

CFE/IAFM+

13A FUEL <IAFM+>

Check item
23 Battery Voltage
Always
78 ± 12 V
Power Supply
Battery Voltage
± 12 V
31
Power Ground Ignition switch: OFF ±0V
47
62 Fuel pump relay
Condenser fan mo-
79
tor relay
Radiator fan motor
6 Battery Voltage
relay Ignition switch: ON
± 12 V
74 A/C relay
46 Starter relay
Main relay (Power
63
supply)
90
91
77
Injector – 1
Injector – 2
Injector – 3
T
While engine is idling after having
warmed up, suddenly depress the accel-
From 11-14 V ,
momentarily
AF
erator pedal. drops slightly
92 Injector – 4
61 Tank Purge Valve Running at 90 °C (194 °F)-105 °C (221 °F) 0V-3V
• Engine: Warm, idle (radiator fan:
OFF)
Alternator G termin- 0.4-0.8 V to 0.8-
23 • Headlamp: OFF→ON
al 1.2 V
• Rear defogger switch switch:
R
OFF→ON
9-13 V (After sev-
Engine warning Ignition switch:
5 eral seconds have
lamp OFF→ON
D
elapsed)
Turn the A/C switch
0-3 V
OFF
43 A/C switch Engine: Idle speed Turn the A/C switch
Battery Voltage
OFF (A/C com-
12 V
pressor is opening)
65 Ignition switch-ST Engine: Cranking 8 V or more
Front oxygen sensor
95 Ignition switch: ON 0-3 V
heater
70 5V
Front oxygen sensor Ignition switch ON
56 410 mv ± 41 mv

FUEL <IAFM+> 13A

Check item
When intake air
temperature is at
3.0 V ± 0.6 V
room temperature
Intake air temperat- 27 °C (80.6 °F)
ure sensor (Com- When intake air
bined map & mat temperature is 40 1.5 - 2.1 V
sensor) °C (104 °F)
When intake air
temperature is 80 0.4 -1.0 V
°C (176 °F)
37 Vacuum sensor ±5V
68 (Combined Map & Ignition switch: ON 4 V ± 0.21 V
54 Mat Sensor) ±0V
84 Ignition switch: ON ±5V
When intake air
temperature is at
3.0 V ± 0.6 V
Engine coolant tem-

perature sensor
T room temperature
27 °C (80.6 °F)
When engine
AF
ure is 40 °C (104 °F)
When engine
ure is 80 °C (176 °F)
39 — ±5V
R
Throttle position Ignition switch: ON

72 — ±0V
Throttle valve
71 closed
sensor 1
D
Ignition switch: ON Throttle valve open 4.65 V ± 0.5 V

(move the throttle
valve manually) Throttle valve
87 closed
sensor 2
Throttle valve open 0.35 V ± 0.5 V
Camshaft sensor
Crankshaft sensor

13A FUEL <IAFM+>

Check item
Approximately 5
27
Pedal at all condi- V
12
Sensor 1 V
19
Ignition switch: ON
Approximately
11
Pedal at all condi- 2.5 V
20
Sensor 2 V
67
Push the main Approximately 12
24
switch V
Push the ACC set/ Approximately 12
22
Cruise Control Ignition switch Z: RESUME switch V
28
Switch ON
T Push the COAST/

SET switch
Approximately 12
V
AF
Push the cencel Approximately 0
81
switch V
66
Key Ring Antenna Ignition switch: ON 1.5-4.0 V
3
Approximately 0
50
V
R
Knock Sensor Ignition switch: ON

Approximately
34
2.5 mv ± 0.5 mv
D
80 Ignition Coil – 2 Approximately

Ignition switch: ON
96 Ignition Coil – 3 0.38 V± 0.02 V
Brake pedal press ±0V
82 At all condition Brake pedal release Battery Voltage
± 12 V
Brake Light Switch
Approximately
Brake pedal press
Brake pedal release 11~14 V
Approximately
1
1.908 V ± 0.2 V
Can Interface Ignition switch: ON
Approximately
9
3.136 V ± 0.2 V
Set selector level to
0V
P or N
42 Start lock Ignition switch: ON
Set selector lever to
12 V
other than P or N

FUEL <IAFM+> 13A

Check item
Engine running Engine at 900 rpm 30 Hz
(Using a digital mul-
75 Engine speed signal
timeter, switch to Engine at 3000 rpm 100 Hz
frequency mode)
CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS WCH13ASHOOT11376
1. Turn the igniton switch to OFF.

2. Disconnect the engine-ECU connector.
3. Measure the resistance and check for continuity between the terminal of the engine-ECU harness-
side connector while referring to the check chart.
NOTE
(1) When measuring resistance and checking continuity, a harness for checking contact pin pressure
should be used instead of inserting a test probe.
(2) All the sensors must be in room temperature 27 °C (80.6 °F) and at adle position.
(3) Check need to be carried out in the order given in the chart.
CAUTION
T
If the terminals that should be checked are mistaken, or if connector terminal are not correctly
shorted to earth, damage may be caused to the vehicle wiring, sensors, engine-ECU and/or ohmmeter.
Be careful to prevent this!
AF
(4) If the ohmmeter shows any deviation from the standard value, check the corresponding sensor,
actuator and related electrical wiring, and then repair or replace.
(5) After repair or replacement, recheck with the ohmmeter to confirm that the repair or replacement
has corrected the problem.
R
D
DOIQC13AR11114
Terminal No.
(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)
16 – 8 Throttle actuator Less than5 Ω

13A FUEL <IAFM+>
Terminal No.
(harness side)
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
12.0 Ω ± 2.4 Ω
Less than1.0 Ω
T
AF
R
D

FUEL <IAFM+> 13A
INJECTOR / 179
INJECTOR WCH13ASASSY11007
T
AF
R
DOIQC13AR12001
D
— Lubricate all O-rings injector with engine oil during reassembly

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

13A FUEL <IAFM+>
/ 180 INJECTOR
2. While turning the injector and high-pressure fuel hose to the right and left, install the delivery
pipe, while being careful not to damage the O-ring. After installing, check that the hose turns
smoothly.
3. If it does not turn smoothly, the O-ring may be trapped, remove the fuel rail pressure and then
reinsert it into the delivery pipe and check once again.
T
AF
R
D

FUEL <IAFM+> 13A
INJECTOR / 181
REMOVAL OF INJECTORS
Symbol Description
A Injector clip
B Fuel rail
C Injector

Before install the no-return valve, ensure the
arrow direction to electronic throttle body.
T Symbol
A
B
Description
No-return valve
Arrow
AF
DOIME11AR07014
INSTALLATION OF INJECTORS
1. Fit a new O-ring, on the injector.
R
Symbol Description
A O-ring
D
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

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

13A FUEL <IAFM+>
/ 182 INJECTOR

Symbol Description
D Injector clip
E Injector slot
DOIME13BR07006
T
AF
R
D

FUEL <IAFM+> 13A
ECU / 183
ECU WCH13ASASSY11008
T
AF
R
DOIMC13AR11109
D

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

13A FUEL <IAFM+>
/ 184 ECU
FLOOR CONSOLE REMOVAL

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

or).
AF
R
D
DOIMC023R11176

connector lock.
DOIMC023R11183

FUEL <IAFM+> 13A
ECU / 185
4. Disconnect the ECU connector (big connect-

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

R
ECU INSTALLATION
the ECU.
D
CAUTION
After install the ECU , ensure the connectors fits
in firmly on TCU or ECU pin.
FLOOR CONSOLE INSTALLATION

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

13A FUEL <IAFM+>
/ 186 FUEL TANK
FUEL TANK WCH13ASASSY11009
T
AF
R
DOINC13AR08001
D
• Draining the fuel.
• Reduce the inner pressure of fuel line and hose. (Refer to On-Vehicle Sevice: Fuel pressure check)
• Remove the rear seat (Refer to MODULE 1.10, GROUP 52A — REAR SEAT).
• Remove the exhaust pipe (Refer to MODULE 1.3, GROUP 015 — EXHAUST PIPE).
• Remove pressure, return and purge tube, and levelling and filler hose (Refer to page
WCH13ASPROC407)
• Install pressure, return and purge tube, and levelling and filler hose.
• Install the exhaust pipe (Refer to, MODULE 1.3, GROUP 015 — EXHAUST PIPE).
• Install the rear seat (Refer to, MODULE 1.10, GROUP 52A — REAR SEAT).
• Refilling the fuel.
• Checking the fuel leaks.

FUEL <IAFM+> 13A
FUEL TANK / 187
Removal steps 8. Tube assy purge

1. Tube assy return 9. Tube assy vapour
2. Tube assy main 10. Cannister assy
3. Fuel tank assy 11. Tube roll over valve assy
4. Braket pump 12. Gasket roll over valve
5. Fuel pump module 13. Fuel filter assy
6. Hose, leveling 14. Heater protector assy
7. Hose filler
T1: 0.4~0.6 Kgf.m
T2: 0.2~0.3 Kgf.m
T3: 0.3 Kgf.m
T
AF
R
D

13A FUEL <IAFM+>
/ 188 FUEL TANK
PRE REMOVAL SERVICE POINT

WCH13ASPROC11014
FUEL TANK ASSY PRE REMOVAL

1. Remove the hose levelling clamp and hose
filler clamp.
Symbol Description
A Hose levelling clamp
B Hose filler clamp
DOINC13AR08003
2. Remove the brake cable bracket (RH) and

(LH) as shown in the illustration.
Symbol Description
A Brake cable bracket
T
AF
DOINC13AR08004
3. Disconnect the pressure tube from fuel filler

assy.
R
Symbol Description
A Fuel filler assy
B Pressure tube
D
(marked with red tag)
DOINC13AR08010
4. Disconnect the purge tube from canister

tube.
Symbol Description
A Purge tube
(marked with yellow tag)
B Tube to canister
DOINC13AR08011

FUEL <IAFM+> 13A
FUEL TANK / 189
5. Disconnect the purge return tube from canis-

ter tube.
Symbol Description
A Purge return tube
(marked with green tag)
B Tube to canister
DOINC13AR08012
6. Remove the bolts (LH) and (RH) to release

the strap assy bolts.
Symbol Description
A Strap assy bolt
T
AF
DOINC13AR08006
7. Carefully lift down the fuel tank module.

NOTE:
Cover the hoses connection with rags to
R
prevent of fuel residual in the fuel pipe line

from flowing out.
D
DOINC13AR08013

13A FUEL <IAFM+>
/ 190 FUEL TANK
NOTE
T
AF
R
D

COOLING <CFE> 14
Content /1
14 COOLING <CFE>
SERVICE SPECIFICATIONS ........................................................... 14/2

LUBRICANT ........................................................................... 14/2
SEALANTS ............................................................................ 14/2
COOLING ................................................................................ 14/3

TROUBLESHOOTING ................................................................ 14/3
ON-VEHICLE SERVICE ................................................................ 14/3

ENGINE COOLANT LEAK CHECKING ............................................ 14/3
RADIATOR CAP VALVE OPENING PRESSURE CHECK ......................... 14/4
ENGINE COOLANT REPLACEMENT .............................................. 14/4
CONCENTRATION MEASUREMENT ............................................. 14/5
ENGINE COOLANT FILLING AND BLEEDING PROCESS ....................... 14/5
FILLING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/5
COOLANT TEMPERATURE SENSOR ................................................ 14/9

REMOVAL SERVICE POINT .........................................................
T 14/10
14/11
AF
THERMOSTAT .......................................................................... 14/12
REMOVAL SERVICE POINTS ....................................................... 14/13
INSTALLATION SERVICE POINTS .................................................. 14/13
INSPECTION .......................................................................... 14/14
THERMOSTAT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/14
WATER PUMP .......................................................................... 14/16

R

INSTALLATION SERVICE POINT ................................................... 14/17
D
WATER HOSE / WATER PIPE AND OIL COOLER .................................. 14/18
WATER HOSE AND WATER PIPE .................................................... 14/19

REMOVAL AND INSTALLATION SERVICE POINTS ............................. 14/19
INSPECTION ......................................................................... 14/20
WATER PIPE AND HOSE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/20
THERMOSTAT PIPE REMOVAL .................................................... 14/21
REMOVAL SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/21
RADIATOR ............................................................................. 14/23

INSTALLATION SERVICE POINTS ................................................. 14/25
INSPECTION .......................................................................... 14/26
RADIATOR FAN MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/26
RADIATOR FAN RELAY (A) CONTINUITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/26
OIL COOLER ........................................................................... 14/27

RECIRCULATION PUMP ............................................................... 14/31

14 COOLING <CFE>
The cooling system is designed to keep every component inside the engine at appropriate temperature
in whatever condition the engine may be operated. The cooling method is of the water-cooled,
pressure forced circulation type in which the water pump pressurizes coolants and circulates it
throughout the engine.
If the coolant temperature exceeds the prescribed temperature, the thermostat opens to circulate the
coolant through the radiator as well so that the heat absorbed by the coolant may be radiated into
the air.
The water pump is of the centrifugal type and is driven by the timing belt or drive belt from the
crankshaft. The radiator is the corrugated fin, down flow type and is cooled by the electrical radiator
fan. The electrical radiator fan is controlled by the engine ECU in accordance with the engine running
condition.
SERVICE SPECIFICATIONS WCH014SPECS12001
Item Specifications
Water-cooled pressurized, forced circula-
Cooling method type tion
T
with electrical fan
Radiator type Pressurized corrugated fin type
Thermostat type Wax pellet type with jiggle valve
AF
Water pump type Impeller of centrifugal type
High pressure valve opening pressure of radiator cap 88 kPa (12.52 psi,
26.57 in.Hg) ± 14.7
-
kPa (2.09 psi, 4.44
in.Hg)
R
Range of coolant antifreeze concentration of radiator % 30 % -

0.2 mm (0.008 in) 89 °C (192.2 °F) ± 2
Start to open valve lift at
Thermostat °C (35.6 °F)
D
Full-open valve lift MIN. at 9 mm (0.35 in) 92 °C (197.6 °F)

LUBRICANT
Items Quantity
Engine coolant 1.3
approx. 7 lit (7.37 U.S.qts,
Weston 936
6.08 Imp.qts)
SEALANTS
Items Specified sealant Remarks
Cylinder block drain plug 3M Nut Locking Part No. 4171
Drying sealant
Engine Coolant Temperature or equivalent
Water pump,Thermostat Proton Genuine Part No.
Semi-drying sealant
MD970389 or equivalent

COOLING <CFE> 14
COOLING /3
COOLING WCH014SHOOT12001
TROUBLESHOOTING
Symptom Probable cause Remedy
Low coolant level Coolant leaks from radiator. Repair or replace
Loose or damaged radiator hose. Retighten or replace
Coolant leaks from water pump Repair or replace
Clogged radiator Contaminated coolant Replace the coolant
Faulty radiator cap Replace
Faulty thermostat Replace
Operational malfunction of fan motor Replace
Loose tension or cut belt Adjust or replace
Abnormal low coolant Faulty thermostat Replace
Faulty temperature gauge or wiring Repair or replace
Inoperative electrical Damaged Thermosensor Replace/overhaul
cooling fan Electrical motor
Radiator fan relay
Wiring
No rise in temperature Faulty thermostat Replace
T ON-VEHICLE SERVICE WCH014SPROC12001

AF
ENGINE COOLANT LEAK CHECKING
1. Confirm that the coolant level is up to the
filler neck.
Install a radiator cap tester and apply 160
kPa (22.76 psi, 48.3 in.Hg) pressure, and then
check for leakage from the radiator hose or
R
connections.
Symbol Description
D
A Cap Adapter
DOIHC014R04002
B Adapter
CAUTION
(1) Be sure to completely clean away any
moisture from the places checked.
(2) When the tester is taken out, be careful
not to spill any coolant from it.
(3) Be careful, when installing and removing
the tester and when testing, not to de-
form the filler neck of the radiator.
2. If there is leakage, repair or replace the ap-
propriate part.

14 COOLING <CFE>
/4 COOLING
RADIATOR CAP VALVE OPENING

PRESSURE CHECK
1. Use a cap adapter (A) to attach the cap to
the tester.
Symbol Description
A Cap adapter
2. Increase the pressure until the indicator of
the gauge stop moving.
Standard value:
88 kPa (12.52 psi, 26.57 in.Hg)± 14.7 kPa (2.09
DOIHC014R04003 psi, 4.44 in.Hg)
3. Replace the radiator cap if the reading does

not remain at or above the limit.
NOTE
Be sure that the cap is clean before testing ,
since rust or other foreign material on the
cap seal will cause an improper indication.
T ENGINE COOLANT REPLACEMENT

1. Drain the engine coolant by removing the
AF
drain plug (B) and then the radiator cap (A).
Symbol Description
A Radiator cap
C Reserve tank
R
D Loosen
D
DOIHC014R04004
2. Remove the drain plug (E) from the cylinder

block to drain.
Symbol Description
E Drain plug (cylinder block)
T1 1.5 kgm (15 Nm, 10.85 ft.lbs)
± 0.2 kgm (2 Nm, 1.45 ft.lbs)
3. Remove the reserve tank (C) to drain the
engine coolant.
4. When the engine coolant has drained, pour
in water from the radiator cap (A) to clean
the engine coolant line.
DOIGC014R03001

COOLING <CFE> 14
COOLING /5
CONCENTRATION MEASUREMENT
Measure the temperature and specified gravity
of the engine coolant to check the antifreeze
concentration.
Standard value: 30% (allowable concentration
range)
tion
Weston 936 30%
DOIHC014R04006 Quantity of coolant Standard value: ap-
prox. 7 lit (7.37 U.S.qts,
6.08 Imp.qts)
CAUTION
If the concentration of the antifreeze is below
30%, the anti-corrosion property will be ad-
versely affected. In addition, if the concentration
T is above 60%, both the anti-freezing and engine

cooling properties will decrease, affecting the
engine adversely. For these reasons, be sure to
AF
maintain true concentration level within the
specified range.
ENGINE COOLANT FILLING AND BLEEDING

PROCESS WCH014SPROC12002
FILLING PROCEDURE
R
1. Check that the drain plug is screwed on

tightly.
Symbol Description
D
A Radiator Cap
C Reserve tank
D Tighten
DOIHC014R04005
2. Open the bleed screw on thermostat hous-

ing.
tank (open cap).
flows out in a continous jet from the bleeder.
Symbol Description
A Water pipe
B Bleed screw
1.2-1.5 kgm (12-15 Nm, 8.68-
T1
10.85 ft.lbs)
DOIHC014R04007

14 COOLING <CFE>
/6 COOLING
5. Start the engine and rev at 2500 rpm.
Symbol Description
1 ACC ⇒ Position
Depress the accelerator pedal
A
⇒ Rev engine until 2500 rpm
T
AF
DOIQC014R12003

flows for a period of 4 minutes while revving
R
engine at 2500 rpm. (During this 4 minutes

period & at 2500 rpm, make sure close the
radiator upper tank with its cap).
D
DOIHC014R04009
BLEEDING PROCEDURE
tightly.
Symbol Description
A Radiator cap
B Drain plug radiator
C Reserve tank
D Tighten
DOIHC014R04005

COOLING <CFE> 14
COOLING /7

ing.
Symbol Description
A Water pipe
B Bleed screw
1.2-1.5 kgm (12-15 Nm, 8.68-
T1
10.85 ft.lbs)
DOIHC014R04007

stops).
Symbol Description
A 20 minutes
T B
C
2500 rpm meter position
Radiator fan auto-stops
AF
R
D
DOIQC014R12004

14 COOLING <CFE>
/8 COOLING

level.
CAUTION
engine is warm.
Symbol Description
A Coolant cover close
B ”MAX” level
Coolant at correct level ⇒ (Add
C
D Pump hose
E Pump
T Antifreeze
Weston 936
Allowable concentration range
30 %
AF
Quantity of Standard value : approx. 7 lit
coolant (7.37 U.S.qts, 6.08 Imp.qts) or
make sure the coolant is filled
DOIHC014R04011
and bled as explained above
R
D

COOLING <CFE> 14
COOLANT TEMPERATURE SENSOR /9
COOLANT TEMPERATURE SENSOR WCH014SASSY11016
T
AF
R
DOINC014R11001
D
Removal steps
1. Coolant temperature sensor
T1 : 2.5-2.9 kgm (25-29 Nm, 18.08-20.98 ft.lbs)

14 COOLING <CFE>
/ 10 COOLANT TEMPERATURE SENSOR
REMOVAL SERVICE POINT WCH014SPROC12003
ENGINE COOLANT TEMPERATURE SENSOR

REMOVAL
1. Use special tool to remove the engine coolant
temperature sensor.
T
AF
DOIKC014R03003
Symbol Description
Engine coolant temperat-
A
R
ure sensor
B Cylinder head
Special Tool Part Number
1
D
MD998770
CAUTION
section) with the special tool when removing
and installing.
DOIHC014R04018
ENGINE COOLANT TEMPERATURE SENSOR CHECK

Refer to GROUP 13A FUEL-Engine Coolant Tem-
perature Sensor Check.
DOIHC014R04019

COOLING <CFE> 14
COOLANT TEMPERATURE SENSOR / 11

WCH014SPROC12004

INSTALLATION
1. If the engine coolant temperature is to be
reused, apply the specified sealant to its
thread.
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent.

DOIHC014R04020 value greatly, replace the sensor.
3. Use special tool to tighten the engine coolant
temperature sensor to the specified torque.
Symbol Description
1 Special Tool Part Number
MD998770
T
Tightening torque:
2.2 kgm (22 Nm, 15.91 ft.lbs) - 2.6 kgm (26 Nm,
18.81 ft.lbs)
AF
CAUTION
DOIHC014R04018 section) with the special tool when removing
and installing.
R
D

14 COOLING <CFE>
/ 12 THERMOSTAT
THERMOSTAT WCH014SASSY11017
T
AF
R
DOIHC014R11010
D
Pre-removal and Post installation Operation

• Engine coolant draining and supplying
• Air cleaner removal and Installation
Removal steps
1. Radiator lower hose clamp
2. Radiator lower hose
3. Retainer clip
4. Washer
5. Thermostat
6. Thermostat seal

COOLING <CFE> 14
THERMOSTAT / 13
REMOVAL SERVICE POINTS WCH014SPROC11021
THERMOSTAT REMOVAL
1. Remove radiator lower hose connection by
untighten 2 pieces radiator hose clamps.
2. Remove the retainer clip by using circlip plier
as shown in the illustration and then remove
the thermostat from the thermostat pipe.
Symbol Description
A Thermostat
B Retainer clip
DOIHC014R04013
T THERMOSTAT INSTALLATION
1. Install the thermostat as shown in the illus-
AF
tration.
Symbol Description
A Thermostat pipe
B Thermostat seal
C Thermostat
R
D Washer
DOIHC014R11011
E Retainer clip
D

14 COOLING <CFE>
/ 14 THERMOSTAT
2. Securely fit the washer and insert retainer

clip by using circlip plier inside the thermo-
stat pipe.
NOTE
(1) Make sure the thermostat position at
hole marking (Angle 25˚±5˚)
(2) Make sure the retainer clip holes facing
downwards.
(3) Make sure the thermostat washer and
retainer clip are located inside the groove
area.
Symbol Description
A Thermostat case
B Thermostat seal
C Thermostat
D Washer
E Retainer clip
F Groove area
T CAUTION
Please ensure that no oil is adhering to the rub-
ber ring of the thermostat. In addition, be careful
AF
do not to fold over or scratch the rubber ring
during installation. If the rubber ring is dam-
DOIHC014R11012 aged, replace the thermostat.
INSPECTION
THERMOSTAT CHECK
R
1. Immerse the thermostat in water and heat

the water while stirring. Check the thermo-
stat valve opening temperature.
D
Standard value:
Items Standard Limit

Valve open-
0.2 mm (0.008 82 ± 2 °C
ing temper-
in) (179.6 ± 3.6 °F)
ature
DOIHC014R04016 2. Check that the amount of valve lift is at the
standard value when water is at the full-
opening temperature.
Standard value:

Full-
open
9 mm (0.35
valve 96 °C (204.8 °F)
in)
lift
MIN. at
NOTE
Measure the valve height when the thermostat
is fully closed and use this measurement to calcu-

COOLING <CFE> 14
THERMOSTAT / 15
late the valve height when the thermostat is fully

opened.
T
AF
R
D

14 COOLING <CFE>
/ 16 WATER PUMP
WATER PUMP WCH014SASSY11018
T
AF
R
DOIHC014R11014
D
— Non-reusable part
Pre-removal and Post-Installation Operation
• Engine coolant draining and suppling.
• Fead belt and tv damper pulley.
• Timing belt.
Removal steps
2. Water pump
3. Water pump gasket
A : Bolt specifications and screw length (mm)
a : 10 x 1.25 x 70
b : 10 x 1.25 x 100
B : Water pump gasket
T1 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T2 : 0.82 kgm (8.2 Nm, 5.93 ft.lbs) ± 0.246 kgm (2.46 Nm, 1.78 ft.lbs)

COOLING <CFE> 14
WATER PUMP / 17

WCH014SPROC12005
WATER PUMP PULLEY INSTALLATION

1. Align water pump pulley with water pump
boss on the front case. Ensure “FRONT”
marking with punch mark facing outward.
2. Fit bolts and tighten to the specified torque.
Specified torque :
0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Symbol Description
A Water pump pulley
B Water pump boss
C Bolts
D “FRONT” marking
T
AF
DOIGE11AR03003
R
D

14 COOLING <CFE>
/ 18 WATER HOSE / WATER PIPE AND OIL COOLER
WATER HOSE / WATER PIPE AND OIL COOLER WCH014SASSY11019
T
AF
R
DOIHC014R11013
D
– Non-reusable part
• Engine coolant draining and supplying (Refer to MODULE 1.2, GROUP 14)
• Air cleaner and air intake hose (Refer to MODULE 1.3, GROUP 15)
Removal steps
1. Radiator upper hose 5. Washer
2. Return hose 6. Thermostat
7. Thermostat seal
3. Thermostat assembly pipe
4. Retainer clip
T1 : 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)

COOLING <CFE> 14
WATER HOSE AND WATER PIPE / 19
WATER HOSE AND WATER PIPE

WCH014SPROC11022
REMOVAL AND INSTALLATION SERVICE

POINTS
REMOVAL RADIATOR LOWER HOSE /
RADIATOR UPPER HOSE CONNECTION
drain plug and the radiator cap.
2. Remove the drain plug from the cylinder
block to drain the engine coolant.
DOIGC014R07004 3. Open the air bleed bolt.
4. Remove clip hose
INSTALLATION RADIATOR LOWER HOSE /

RADIATOR UPPER HOSE CONNECTION
1. Make sure the hose mating mark white col-
our facing upward.
T Symbol
1
Description
White mark facing upward
2. Insert the hose until end of the bulge area
AF
of the engine inlet or engine outlet pipe.
Symbol Description
A 32 mm (1.26 in)
B Hose clamp
C Radiator hose
R
D Bulge area
T1 1.2 kgm (12 Nm, 8.68
ft.lbs)
D
E Engine inlet / outlet pipe

DOIGC014R03016
3. Align the mating marks on the radiator hose

and hose clamp, and then connect the radi-
ator hose.
Symbol Description
A 32 mm (1.26 in)
B Radiator hose
C Bulge area
D Hose clip
E Steel/ Plastic pipe
DOIGC014R03032

14 COOLING <CFE>
/ 20 WATER HOSE AND WATER PIPE
THERMOSTAT PIPE ASSEMBLY AND SEAL

INSTALLATION
seal of the thermostat pipe assembly. Push
lightly while turning the thermostat pipe
assembly to the right and left towards the
water pump case assembly without dam-
aging the seal. After installation check that
the thermostat pipe assembly turns smoothly.
Symbol Description
DOINC014R11002 A Thermostat pipe assembly
B Seal
C Return hose
is probably being clamped. Disconnect the
thermostat pipe assembly and check the seal.
Then, re-insert the new thermostat pipe as-
sembly seal and repeat procedure no.1 as
T above.
Symbol Description
AF
C Front Seal
D Impeller
E Water pump
R
INSPECTION
WATER PIPE AND HOSE CHECK
D
Check the water pipe and hose for cracks, dam-

age, clog and replace it if necessary.
DOIHC014R04026

COOLING <CFE> 14
THERMOSTAT PIPE REMOVAL

WCH014SPROC11023

1. Remove thermostat pipe bolt (D) as shown
Symbol Description
A Cylinder head
B Thermostat pipe
C Bolt
DOIGC014R11002
2. Remove thermostat pipe hose clip (H) using

circlip plier.
Symbol Description
D Alternator
E Circlip plier
T
F Timing belt cover
G Thermostat pipe hose clip
AF
DOIGC014R11003
3. Pull completely the thermostat pipe hose

from the pipe (J) as shown in the illustration.
R
Symbol Description
H Thermostat pipe hose
I Thermostat pipe
D
DOIGC014R11004
4. Remove Intake Manifold (J) completely from

the engine.
DOIGC014R11005

14 COOLING <CFE>
5. Remove 1 pc of thermostat pipe bolt (K),

which located in the middle of the thermo-
stat pipe.
DOIGC014R11006
6. Pull thermostat pipe slowly and carefully as

T
AF
DOIGC014R07004
THERMOSTAT PIPE ASSY INSTALLATION

R
seal (A) of the thermostat pipe (B) assembly.

Press into the water pump case assembly
while turning it left and right . Be careful
not to damage the seal. After installation,
D
check that the thermostat pipe assembly

turns smoothly.
DOIGE11AR06135 for damage. After that, re-insert the new
procedure no.1 as above.
3. Tighten the themostat pipe bolts to the spe-
cified torque.
Specified torque (T1) :
2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)

COOLING <CFE> 14
RADIATOR / 23
RADIATOR WCH014SASSY11020
T
AF
R
D
DOIQC014R11003

14 COOLING <CFE>
/ 24 RADIATOR
• Engine coolant draining (Refer to MODULE 1.2, GROUP 14)
• Air cleaner removal and installlation (Refer to MODULE 1.3, GROUP 15)
• CVT oil supplying and checking (Refer to MODULE 1.5, GROUP 23)
Post-installation operation
• Engine coolant supplying (Refer to MODULE 1.2, GROUP 14)
• CVT oil supplying and checking (Refer to MODULE 1.5, GROUP 23)
• Air cleaner removal and installlation (Refer to MODULE 1.3, GROUP 15.)
Radiator removal steps Radiator fan motor removal steps
1. Drain plug 1. Drain plug
2. Radiator cap 2. Radiator cap
3. Overflow hose 3. Overflow hose
4. Reserve tank 5. Radiator upper hose
5. Radiator upper hose 12. Shroud
6. Radiator lower hose 15. Radiator fan
16. Radiator fan motor
7. CVT oil cooler hose connection
8. Upper insulator
9. Radiator assembly
10. Lower insulator
11. CVT oil cooler hose assembly
12. Shroud
13. A/C fan
T
AF
14. A/C fan motor
15. Radiator fan
16. Radiator fan motor assembly
T1 : 1.2 kgm (12 Nm, 8.68 ft.lbs)
T2 : 0.98 kgm (9.8 Nm, 7.09 ft.lbs)
R
D

COOLING <CFE> 14
RADIATOR / 25

WCH014SPROC11024
RADIATOR LOWER AND UPPER HOSE

CONNECTION INSTALLATION
NOTE:
Before installing the radiator hose, ensure the
white colour hose mating mark is facing upward.
Symbol Description
1 White colour mark facing
upward
DOIQC014R12007
T of the engine inlet or engine outlet pipe.
Symbol Description
AF
A 32 mm (1.26 in)
B Hose clamp
C Radiator hose
D Bulge area
T1 1.2 kgm (12 Nm, 8.68
R
ft.lbs)
DOIGC014R03016

D

ator hose.
Symbol Description
A 32 mm (1.26 in)
B Radiator hose
C Bulge area
D Hose clip
DOIGC014R03032

14 COOLING <CFE>
/ 26 RADIATOR
INSPECTION
RADIATOR FAN MOTOR CHECK
1. Check the radiator fan rotation when battery
voltage is applied between terminals (as
shown in the illustration).
2. Check any abnormal noise during turning
the fan motor.
DOIIC014R9023
RADIATOR FAN RELAY (A) CONTINUITY CHECK

Battery Continuity
voltage
Not —
supplied
T
Terminal No.1 (+) connect → termin-
al No.3 (-).
Supplied
Terminal No.4 connect → terminal
AF
No.5.
Symbol Description
A Radiator fan relay
R
D
DOINC014R09007

COOLING <CFE> 14
OIL COOLER / 27
OIL COOLER WCH014SASSY11021
T
AF
R
DOIGC014R11023
D
Oil cooler removal steps
1. Oil cooler
2. Hose oil feed
3. Hose coolant return
4. Hose coolant feed
5. Hose oil return
T1 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T2 : 3.3 - 3.5 kgm (33 - 35 Nm, 23.87 - 25.32 ft.lbs)

14 COOLING <CFE>
/ 28 OIL COOLER
OIL COOLER REMOVAL

1. Remove intake manifold (Refer to page
WCH015SASSY11008).
2. Open radiator cap and drain the coolant.
3. Disconnect the rear oxygen sensor connector
from the oil cooler bracket.
DOIGC014R11037
T 4. Disconnect the oil pressure switch connector.

AF
R
DOIGC014R11038
D

COOLING <CFE> 14
OIL COOLER / 29
5. Remove oil cooler bracket bolts (E).

CAUTION
Loosen bracket first, then detach the oil
cooler hose (from side).
6. Release all oil cooler hose clamp as shown in
the illustration.
Symbol Description
A Oil feed hose
B Oil return hose
C Feed coolant hose
D Return coolant hose
E Oil cooler bracket bolts
F Oil cooler
T
AF
DOINE11AR11012
7. Release the hose clamp and detach the oil

cooler hose from coolant pipe.
R
D
DOIGC014R11041
8. Release and remove the oil cooler hose from

front case.
DOIGC014R11042

14 COOLING <CFE>
/ 30 OIL COOLER
9. Remove out oil cooler bracket.
DOIGC014R11043
10. Remove water pump hose at front case area

from oil cooler pipe.
T
AF
DOIGC014R11044
11. Remove oil cooler.

R
D
DOIGC014R11045

COOLING <CFE> 14
RECIRCULATION PUMP / 31
RECIRCULATION PUMP WCH014SASSY11023
T
AF
R
DOINC014R11004
D
Removal steps
1. Hose pump (Turbo)
2. Hose pump (Block)
3. Recirculation Pump
T1 : 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)

14 COOLING <CFE>
/ 32 RECIRCULATION PUMP
NOTE
T
AF
R
D

COOLING <IAFM+> 14
Content /1
14 COOLING <IAFM+>
SERVICE SPECIFICATIONS ........................................................... 14/2

LUBRICANT ........................................................................... 14/2
SEALANTS ............................................................................ 14/2
COOLING ................................................................................ 14/3


ENGINE COOLANT LEAK CHECKING ............................................ 14/3
RADIATOR CAP VALVE OPENING PRESSURE CHECK ......................... 14/4
ENGINE COOLANT REPLACEMENT .............................................. 14/4
CONCENTRATION MEASUREMENT ............................................. 14/5
ENGINE COOLANT FILLING AND BLEEDING PROCESS ....................... 14/5
FILLING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/5
COOLANT TEMPERATURE SENSOR ................................................ 14/9

T 14/10
14/11
AF
THERMOSTAT .......................................................................... 14/12
REMOVAL SERVICE POINT ......................................................... 14/13
INSPECTION .......................................................................... 14/14
THERMOSTAT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/14
WATER PUMP .......................................................................... 14/15

R

D
WATER HOSE AND WATER PIPE .................................................... 14/17

INSTALLATION SERVICE POINTS ................................................. 14/18
INSPECTION .......................................................................... 14/19
WATER PIPE AND HOSE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/19
RADIATOR .............................................................................. 14/20

INSPECTION .......................................................................... 14/23
RADIATOR FAN MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/23
RADIATOR FAN RELAY (A) CONTINUITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14/23

14 COOLING <IAFM+>
The cooling system is designed to keep every component inside the engine at appropriate temperature
in whatever condition the engine may be operated. The cooling method is of the water-cooled,
pressure forced circulation type in which the water pump pressurizes coolants and circulates it
throughout the engine.
If the coolant temperature exceeds the prescribed temperature, the thermostat opens to circulate the
coolant through the radiator as well so that the heat absorbed by the coolant may be radiated into
the air.
The water pump is of the centrifugal type and is driven by the timing belt or drive belt from the
crankshaft. The radiator is the corrugated fin, down flow type and is cooled by the electrical radiator
fan. The electrical radiator fan is controlled by the engine ECU in accordance with the engine running
condition.
Item Specifications
Water-cooled pressurized, forced circula-
Cooling method type tion
T
with electrical fan
Radiator type Pressurized corrugated fin type
Thermostat type Wax pellet type with jiggle valve
AF
Water pump type Impeller of centrifugal type
High pressure valve opening pressure of radiator cap 88 kPa (12.52 psi,
26.57 in.Hg) ± 14.7
-
kPa (2.09 psi, 4.44
in.Hg)
R
Range of coolant antifreeze concentration of radiator % 30 % -

0.2 mm (0.008 in) 89 °C (192.2 °F) ± 2
Start to open valve lift at
Thermostat °C (35.6 °F)
D
Full-open valve lift MIN. at 9 mm (0.35 in) 92 °C (197.6 °F)

LUBRICANT
Items Quantity
Engine coolant 1.3
approx. 7 lit (7.37 U.S.qts,
Weston 936
6.08 Imp.qts)
SEALANTS
Cylinder block drain plug 3M Nut Locking Part No. 4171
Drying sealant
Engine Coolant Temperature or equivalent
Water pump,Thermostat Proton Genuine Part No.
Semi-drying sealant
MD970389 or equivalent

COOLING <IAFM+> 14
COOLING /3
COOLING WCH014SHOOT11001
TROUBLESHOOTING
Low coolant level Coolant leaks from radiator. Repair or replace
Loose or damaged radiator hose. Retighten or replace
Coolant leaks from water pump Repair or replace
Clogged radiator Contaminated coolant Replace the coolant
Faulty radiator cap Replace
Faulty thermostat Replace
Operational malfunction of fan motor Replace
Loose tension or cut belt Adjust or replace
Abnormal low coolant Faulty thermostat Replace
Faulty temperature gauge or wiring Repair or replace
Inoperative electrical Damaged Thermosensor Replace/overhaul
cooling fan Electrical motor
Radiator fan relay
Wiring
No rise in temperature Faulty thermostat Replace
T ON-VEHICLE SERVICE WCH014SPROC11013

AF
ENGINE COOLANT LEAK CHECKING
1. Confirm that the coolant level is up to the
filler neck.
Install a radiator cap tester and apply 160
kPa (22.76 psi, 48.3 in.Hg) pressure, and then
check for leakage from the radiator hose or
R
connections.
Symbol Description
D
A Cap Adapter
DOIHC014R04002
B Adapter
CAUTION
(1) Be sure to completely clean away any
moisture from the places checked.
(2) When the tester is taken out, be careful
not to spill any coolant from it.
(3) Be careful, when installing and removing
the tester and when testing, not to de-
form the filler neck of the radiator.
2. If there is leakage, repair or replace the ap-
propriate part.

14 COOLING <IAFM+>
/4 COOLING
RADIATOR CAP VALVE OPENING

PRESSURE CHECK
1. Use a cap adapter (A) to attach the cap to
the tester.
Symbol Description
A Cap adapter
2. Increase the pressure until the indicator of
the gauge stop moving.
Standard value:
88 kPa (12.52 psi, 26.57 in.Hg)± 14.7 kPa (2.09
DOIHC014R04003 psi, 4.44 in.Hg)
3. Replace the radiator cap if the reading does

not remain at or above the limit.
NOTE
Be sure that the cap is clean before testing ,
since rust or other foreign material on the
cap seal will cause an improper indication.
T ENGINE COOLANT REPLACEMENT

AF
drain plug (B) and then the radiator cap (A).
Symbol Description
A Radiator cap
C Reserve tank
R
D Loosen
D
DOIHC014R04004
2. Remove the drain plug (E) from the cylinder

block to drain.
Symbol Description
E Drain plug (cylinder block)
T1 1.5 kgm (15 Nm, 10.85 ft.lbs)
± 0.2 kgm (2 Nm, 1.45 ft.lbs)
3. Remove the reserve tank (C) to drain the
engine coolant.
4. When the engine coolant has drained, pour
in water from the radiator cap (A) to clean
the engine coolant line.
DOIGC014R03001

COOLING <IAFM+> 14
COOLING /5
CONCENTRATION MEASUREMENT
Measure the temperature and specified gravity
of the engine coolant to check the antifreeze
concentration.
Standard value: 30% (allowable concentration
range)
tion
Weston 936 30%
DOIHC014R04006 Quantity of coolant Standard value: ap-
prox. 7 lit (7.37 U.S.qts,
6.08 Imp.qts)
CAUTION
If the concentration of the antifreeze is below
30%, the anti-corrosion property will be ad-
versely affected. In addition, if the concentration
T is above 60%, both the anti-freezing and engine

cooling properties will decrease, affecting the
engine adversely. For these reasons, be sure to
AF
maintain true concentration level within the
specified range.
ENGINE COOLANT FILLING AND BLEEDING

PROCESS WCH014SPROC11014
FILLING PROCEDURE
R

tightly.
Symbol Description
D
A Radiator Cap
C Reserve tank
D Tighten
DOIHC014R04005

ing.
tank (open cap).
Symbol Description
A Water pipe
B Bleed screw
1.2-1.5 kgm (12-15 Nm, 8.68-
T1
10.85 ft.lbs)
DOIHC014R04007

14 COOLING <IAFM+>
/6 COOLING
5. Start the engine and rev at 2500 rpm.
Symbol Description
1 ACC ⇒ Position
Depress the accelerator pedal
A
⇒ Rev engine until 2500 rpm
T
AF
DOIQC014R12002

flows for a period of 4 minutes while revving
R
engine at 2500 rpm. (During this 4 minutes

period & at 2500 rpm, make sure close the
radiator upper tank with its cap).
D
DOIHC014R04009
BLEEDING PROCEDURE
tightly.
Symbol Description
A Radiator cap
B Drain plug radiator
C Reserve tank
D Tighten
DOIHC014R04005

COOLING <IAFM+> 14
COOLING /7

ing.
Symbol Description
A Water pipe
B Bleed screw
1.2-1.5 kgm (12-15 Nm, 8.68-
T1
10.85 ft.lbs)
DOIHC014R04007

stops).
Symbol Description
A 20 minutes
T B
C
2500 rpm meter position
Radiator fan auto-stops
AF
R
D
DOIQC014R12005

14 COOLING <IAFM+>
/8 COOLING

level.
CAUTION
engine is warm.
Symbol Description
A Coolant cover close
B ”MAX” level
Coolant at correct level ⇒ (Add
C
D Pump hose
E Pump
T Antifreeze
Weston 936
Allowable concentration range
30 %
AF
Quantity of Standard value : approx. 7 lit
coolant (7.37 U.S.qts, 6.08 Imp.qts) or
make sure the coolant is filled
DOIHC014R04011
and bled as explained above
R
D

COOLING <IAFM+> 14
COOLANT TEMPERATURE SENSOR /9
COOLANT TEMPERATURE SENSOR WCH014SASSY12001
T
AF
R
DOIQC014R12008
D
Removal steps
T1 : 2.5-2.9 kgm (25-29 Nm, 18.08-20.98 ft.lbs)

14 COOLING <IAFM+>
/ 10 COOLANT TEMPERATURE SENSOR

REMOVAL
1. Use special tool to remove the engine coolant
temperature sensor.
T
AF
DOIKC014R03003
Symbol Description
Engine coolant temperat-
A
R
ure sensor
B Cylinder head
Special Tool Part Number
1
D
MD998770
CAUTION
section) with the special tool when removing
and installing.
DOIHC014R04018
ENGINE COOLANT TEMPERATURE SENSOR CHECK

Refer to GROUP 13A FUEL-Engine Coolant Tem-
perature Sensor Check.
DOIHC014R04019

COOLING <IAFM+> 14
COOLANT TEMPERATURE SENSOR / 11

WCH014SPROC11016

INSTALLATION
1. If the engine coolant temperature is to be
reused, apply the specified sealant to its
thread.
Specified sealant:

DOIHC014R04020 value greatly, replace the sensor.
3. Use special tool to tighten the engine coolant
temperature sensor to the specified torque.
Symbol Description
1 Special Tool Part Number
MD998770
T
Tightening torque:
2.2 kgm (22 Nm, 15.91 ft.lbs) - 2.6 kgm (26 Nm,
18.81 ft.lbs)
AF
CAUTION
DOIHC014R04018 section) with the special tool when removing
and installing.
R
D

14 COOLING <IAFM+>
/ 12 THERMOSTAT
THERMOSTAT WCH014SASSY11012
T
AF
R
DOIHC014R04036
D
Pre-removal and Post installation Operation

• Engine Coolant Draining and Supplying (Refer to Pub. No RDWE-03DA010, GROUP 14)
• Air Cleaner Removal and Installation (Refer to page WCH015SASSY069)
• Radiator lower hose connection Removal and Installation (Refer to page WCH014SPROC103)
Removal steps
1. Water inlet fitting
3. Retainer clip
4. Washer
5. Thermostat
6. Thermostat seal

COOLING <IAFM+> 14
THERMOSTAT / 13
THERMOSTAT REMOVAL
Remove the thermostat from the thermostat pipe
assembly by using plier.
Symbol Description
A Thermostat
B Retainer clip
DOIHC014R04013

THERMOSTAT INSTALLATION
Install the thermostat as shown in illustration.
T
AF
DOIHC014R04014
1. Fit the washer and insert retainer clip using

clip plier inside thermostat pipe assy securely.
NOTE
R
(1) Make sure the retainer clip holes facing

down.
(2) Make sure the thermostat washer and retain-
er clip are located inside the groove area.
D
Symbol Description
A Thermostat pipe
B Thermostat seal
C Thermostat
D Washer
E Retainer clip
F Groove area
CAUTION
Make absolutly sure that no oil is adhering to
the rubber ring of the thermostat. In addition,
be careful not to fold over or scratch the rubber
ring when inserting. If the rubber ring is dam-
aged, replace the thermostat.
DOIHC014R04015

14 COOLING <IAFM+>
/ 14 THERMOSTAT
INSPECTION
THERMOSTAT CHECK
1. Immerse the thermostat in water and heat
the water while stirring. Check the thermo-
stat valve opening temperature.
Standard value:

Valve open-
0.2 mm (0.008 82 ± 2 °C
ing temper-
in) (179.6 ± 3.6 °F)
ature
DOIHC014R04016 2. Check that the amount of valve lift is at the
standard value when water is at the full-
opening temperature.
Standard value:

Full-open
valve lift 9 mm (0.35 in) 96 °C (204.8 °F)
T NOTE
MIN. at
Measure the valve height when the thermostat

AF
is fully closed and use this measurement to calcu-
late the valve height when the thermostat is fully
open.
R
D

COOLING <IAFM+> 14
WATER PUMP / 15
WATER PUMP WCH014SASSY11013
T
AF
R
DOIMC014R07007
D
• Engine Coolant Draining and Suppling (Refer to Pub. No RDWE-03DA030, GROUP 14)
• Fead Belt and TV Damper Pulley Removal and Installation (Refer to page WCH11ASASSY067)
• Timing Belt Removal and Installation (Refer to page WCH11ASASSY073)
Removal steps
2. Water pump
3. Seal
A : Bolt Specifications and Screw length (mm)
a : 10 x 1.25 x 70
b : 10 x 1.25 x 100
B : 3 . Seal
T1 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)

14 COOLING <IAFM+>
/ 16 WATER PUMP

WCH014SPROC11018

1. Align water pump pulley with water pump
boss on the front case. Ensure “FRONT”
marking with punch mark facing outward.
2. Fit bolts and tighten to the specified torque.
Specified torque :
0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Symbol Description
A Water pump pulley
B Water pump boss
C Bolts
T
AF
DOIGE11AR03003
R
D

COOLING <IAFM+> 14
WATER HOSE AND WATER PIPE WCH014SASSY11014
T
AF
R
DOIMC014R07008
D
- Non-reusable part
• Engine coolant draining and supplying (Refer to Group 14)
• Air cleaner and air intake hose assembly removal and installation ( Refer WCH015SASSY081)
Removal steps
1. Radiator upper hose
2. Radiator lower hose
3. Return hose
4. Thermostat pipe assembly
5. Seal
T1 : 2.2 kgm (22 Nm, 15.91 ft.lbs) - 2.6 kgm (26 Nm, 18.81 ft.lbs)

14 COOLING <IAFM+>

WCH014SPROC11019
RADIATOR LOWER HOSE / RADIATOR UPPER

HOSE CONNECTION
our facing upward.
Symbol Description
1 White mark facing upward
DOIHC014R04022

Symbol Description
A 32 mm (1.26 in)
B Hose clamp
T
C Radiator hose
D Bulge area
T1 1.2 kgm (12 Nm, 8.68 ft.lbs)
AF
DOIHC014R04023

ator hose.
R
Symbol Description
A 32 mm (1.26 in)
D
B Radiator hose
C Bulge area
D Hose clip
DOIHC014R04024
THERMOSTAT PIPE ASSEMBLY AND SEAL

INSTALLATION
seal of the thermostat pipe assembly. Push
lightly while turning the thermostat pipe
assembly to the right and left towards the
water pump case assembly while being
careful not to damage the seal. After in-
stalling, check that the thermostat pipe as-
sembly turns smoothly.
DOIMC014R07009

COOLING <IAFM+> 14
Symbol Description
B Seal
is probably stucked. Disconnect the thermo-
stat pipe assembly and check the seal for
damage. After this, re-insert the new thermo-
stat pipe assembly seal and check the seal
turns smoothly.
Symbol Description
C Front case
D Impeller
E Water pump assy
INSPECTION
T
WATER PIPE AND HOSE CHECK
Check the water pipe and hose for cracks, dam-
age, clog and replace them if necessary.
AF
R
DOIHC014R04026
D

14 COOLING <IAFM+>
/ 20 RADIATOR
RADIATOR WCH014SASSY11015
T
AF
R
DOIQC014R12006
D
• Engine coolant draining (Refer to Pub. No. RDWE-03DA010, GROUP 14)
• Air cleaner removal and installlation (Refer to page WCH015SASSY069)
• A/T Fluid supplying and checking (Refer to Pub. No. RDWE-03DA010, GROUP 23)
• Engine coolant supplying (Refer to Pub. No. RDWE-03DA010, GROUP 14)
• A/T Fluid supplying and checking (Refer to Pub. No. RDWE-03DA010, GROUP 23)
• Air cleaner removal and installlation (Refer to page WCH015SASSY069)

COOLING <IAFM+> 14
RADIATOR / 21
Radiator removal steps Radiator fan motor removal steps

1. Drain plug 1. Drain plug
2. Radiator cap 2. Radiator cap
3. Overflow hose 3. Overflow hose
4. Reserve tank 5. Radiator upper hose
5. Radiator upper hose 12. Door flap
6. Radiator lower hose 14. Fan
15. Radiator fan shroud
7. Transmission fluid cooler hose connection
8. Upper insulator
9. Radiator assembly
10. Lower insulator
11. Transmission fluid cooler hose clamp
12. Door flap
13. Radiator fan motor assembly
T2 : 1.2 kgm (12 Nm, 8.68 ft.lbs)
T
AF
R
D

14 COOLING <IAFM+>
/ 22 RADIATOR

WCH014SPROC11020
RADIATOR LOWER HOSE / RADIATOR UPPER

HOSE CONNECTION
our facing upwards.
Symbol Description
1 White mark facing upwards
DOIQC014R12007

Symbol Description
A 32 mm (1.26 in)
B Hose clamp
T
C Radiator hose
D Bulge area
T1 1.2 kgm (12 Nm, 8.68 ft.lbs)
AF
DOIHC014R04023

ator hose.
R
Symbol Description
A 32 mm (1.26 in)
D
B Radiator hose
C Bulge area
D Hose clip
DOIHC014R04024 TRANSMISSION FLUID COOLER HOSE

REMOVAL
1. After removing the hose from the radiator,
plug the hose and the radiator nipple to
prevent dust or foreign particles from getting
in.

COOLING <IAFM+> 14
RADIATOR / 23
INSPECTION
RADIATOR FAN MOTOR CHECK
1. Check to be sure that radiator fan rotates
when battery voltage is applied between
terminals (as shown in the figure).
2. Check to see that abnormal noises are not
produced, while motor is turning.
DOIHC014R04028
RADIATOR FAN RELAY (A) CONTINUITY CHECK

Battery Continuity
voltage
Not sup-
—
plied
T
Terminal No.1 (+) connect → termin-
al No.2 (-).
Supplied
Terminal No.3 connect → terminal
AF
No.4
Symbol Description
A Radiator fan relay
R
D
DOIMC014R07010

14 COOLING <IAFM+>
/ 24 RADIATOR
NOTE
T
AF
R
D

INTAKE AND EXHAUST <CFE> 15
Content /1
15 INTAKE AND EXHAUST <CFE>

AIR CLEANER .......................................................................... 15/2
REMOVAL AND INSTALLATION .................................................. 15/2
DISASSEMBLY AND REASSEMBLY ................................................ 15/4
INTAKE MANIFOLD ................................................................... 15/7

CONNECTOR HARNESS LOCATION .............................................. 15/7
DISCONNECT CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15/10
DISASSEMBLY AND REASSEMBLY SERVICE POINTS .......................... 15/16
TURBOCHARGER ...................................................................... 15/18

T
ASSEMBLY AND REASSEMBLY SERVICE POINTS ............................... 15/33
AF
SPECIAL TOOL ......................................................................... 15/38
TOOL .................................................................................. 15/38
INTERCOOLER ......................................................................... 15/39

R
INTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15/41
EXHAUST MANIFOLD ................................................................ 15/45

D

EXHAUST PIPE AND MAIN MUFFLER .............................................. 15/50


/2 AIR CLEANER
AIR CLEANER WCH015SASSY11015
T
AF
R
D
DOIQC015R11001

AIR CLEANER /3
Removal steps
1. Full load breather hose .
2. Air cleaner module assy
3. Zip tube
4. Snorkel
T1 : >0.3 kgm (3 Nm, 2.17 ft.lbs)
T2 : <0.3 kgm (3 Nm, 2.17 ft.lbs)
T3 : <0.3 kgm (3 Nm, 2.17 ft.lbs)
T
AF
R
D

/4 AIR CLEANER
DISASSEMBLY AND REASSEMBLY
T
AF
R
DOIQC015R11002
Disassembly steps
1. Snorkel.
D
2. Clamp.
3. Zip tube.
4. Air cleaner housing top assy.
5. Air cleaner element/ pre-filter.
6. Air cleaner housing bottom assy.

AIR CLEANER /5

WCH015SPROC11018
AIR CLEANER MODULE ASSY INSTALLATION

1. Push the air cleaner module assy’s stud firmly
into the insulators on the air box bracket.
Symbol Description
A Studs
B Insulator.
DOIQC015R11005
2. Ensure the anti roll gasket slot fits onto the

air box support bracket.
Symbol Description
A Anti roll gasket slot
B Support bracket
T
AF
DOINC015R11004
3. Fit the zip tube to the compressor.
Symbol Description
R
A Zip tube
B Compressor
D
DOIQC015R11003
4. Tighten the air cleaner module assy with a

bolt into the air box insulators bracket.
Symbol Description
A Air cleaner module assy
B Bolt
C Insulators
Specified torque value (TI): Maximum
0.3 kgm (3 Nm, 2.17 ft.lbs)
DOINC015R11006

/6 AIR CLEANER
5. Press the clip hose and insert full load

breather hose into nipple at cylinder head.
Push the smaller end of the full load breather
hose into the zip tube’s nipple.
Symbol Description
A Clip
B Breather hose
C Cylinder head’s nipple
D Zip tube’s nipple.
NOTE:
DOINC015R11002 Release the clip hose to secure the breather
hose onto the nipple.
6. Lock the full load breather hose into the
holder on the air cleaner module assy.
Symbol Description
A Full load breather hose
B Holder
T C Lock point
AF
DOINC015R11007
7. Fasten the snorkel to the fem by using 2

pieces bolt.
R
Symbol Description
A Snorkel
B Fem
D
C Bolt
Specified torque (T2): Less than
0.3 kgm (3 Nm, 2.17 ft.lbs)
DOIQC015R11006
8. Fasten the zip tube and clamp it’s to the

compressor.
Symbol Description
A Clamp
B Compressor
Specified torque value: Less than
0.3 kgm (3 Nm, 2.17 ft.lbs)
DOIQC015R11004

INTAKE MANIFOLD /7
INTAKE MANIFOLD WCH015SASSY11016
CONNECTOR HARNESS LOCATION
T
AF
R
DOINC015R11047
D
NOTE:
1. Before removing the intake manifold, properly disconnect the battery terminal and engine
harness.
2. During installation, ensure all hoses connections are properly installed.
Disconnection connector harness, hose and duct assy.
1. Breather hose.
2. Engine wiring harness and sub harness sensor connector.
3. Front oxygen sensor connector.
4. Map sensor.
5. Purge solenoid valve connector.
6. Fuel vapor hose.
7. Throttle body actuator connector.
8. Map sensor 2 connector.
9. Vacuum hose.

/8 INTAKE MANIFOLD
T
AF
R
D
DOINC015R11050

INTAKE MANIFOLD /9
Non-reusable parts
• Fuel discharge prevention
• Air cleaner
• Throttle body
• Throttle body
• Air cleaner
Removal steps
1. Purge solenoid valve.
2. Fuel rail harness bracket.
3. Fuel rail module.
4. Intake manifold.
5. Map sensor.
6. Fuel vapor hose.
7. Breather hose.
8. Throttle body harness bracket.
9. Throttle body.
10. Throttle body seal.
11. Intake port seal.
12. Oil cooler bracket bolt.
T
AF
R
D

/ 10 INTAKE MANIFOLD
NEGATIVE BATTERY CABLE FROM THE

BATTERY DISCONNECTION
Disconnect the battery cable (- ve) and tape the
terminal.
CAUTION
Wait at least 5 minutes after disconnected the
battery cable before proceed any further work.
Symbol Description
DOINC015R11053 A Battery cable
B Insulating tape
C Battery
DISCONNECT CONNECTOR
Disconnect the harness connector at engine room
(Refer to 15/7 ).
T HIGH-PRESSURE FUEL HOSE REMOVAL

Remove the high-pressure fuel hose (A) from the
delivery pipe (B) by pressing the connector and
AF
release it from the delivery pipe.
NOTE
Be careful not to damage the connector and hose
line.
Symbol Description
R
Quick connector type; press for-

A
ward the connector and pull
DOINC015R11054
B Delivery pipe
D
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.
FUEL RAIL ASSY REMOVAL

1. Remove 2 pieces bolts at fuel rail assy bracket
harness.
Symbol Description
A Fuel rail assy bracket
B Bolt
DOINC015R11055

INTAKE MANIFOLD / 11
2. Remove 2 pieces bolts at fuel rail assy.
Symbol Description
A Fuel rail assy
B Bolt
DOINC015R11056
3. Remove the fuel rail assy from the intake

manifold assy and disconnect connector har-
ness by releasing the lock pin. Then pull out
all the connector harness properly as shown
Symbol Description
T A
B
Injector connector harness
Lock pin
AF
C Injector
DOINC015R11060

WCH015SPROC11020
R
FUEL RAIL ASSY INSTALLATION

1. Install the fuel rail assy to the intake mani-
fold properly.
D
Symbol Description
A Fuel rail assy
B Injector
C “O” ring
DOINC015R11057 D Intake manifold
CAUTION
Do not damage the “O ring injector while
install the fuel rail assy to the intake mani-
fold.

2. Install 2 pieces bolts fuel rail assy.
Symbol Description
A Fuel rail assy
B Bolt
Specified torque (E and F):
0.72 ft.lbs)
DOINC015R11056
3. Connect all the injector connector harness

properly.
Symbol Description
A Injector harness connector
B Fuel rail assy
T CAUTION
Make sure the injector harness connector is
connected to the injector assy accordingly.
AF
When inserting the connector, make sure
that “click” sound is heard. Once inserted,
DOINC015R11061
try to pull the connector and if it dislocates.
it is not fully connected.

R
INTAKE AIR FUEL MODULE ASSY REMOVAL

1. Remove oil cooler bracket bolts (2 pieces).
D
Symbol Description
A Intake manifold
B Bracket
C Bolt
DOINC015R11045

2. Remove intake manifold bolts (5 pieces) and

nuts (2 pieces) from the cylinder head.
Symbol Description
A Nut
B Bolt
C Intake manifold
DOINC015R11041
3. Remove the intake manifold from the engine

cylinder head carefully.
Symbol Description
A Intake manifold
B Engine cylinder head
T
AF
DOINC015R11058

WCH015SPROC11022
R
INTAKE AIR FUEL MODULE ASSY

INSTALLATION.
1. Install the port seal into the intake manifold
D
groove as per shown in the illustration.
Symbol Description
A Port seal
B Groove
C Intake manifold
DOINC015R11042
2. Install the intake manifold to the engine

cylinder head properly.
Symbol Description
A Intake manifold
B Engine cylinder head
DOINC015R11058

3. Tighten intake manifold bolts (5 pieces) and

nuts (2 pieces) according to the sequence
numbers as shown in the illustration.
Symbol Description
A Engine cylinder head
B Intake manifold
C Nut
D Bolt
Specified torque (C and D):
2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.1 kgm (1
DOINC015R11044 Nm, 0.72 ft.lbs)
NOTE
Fastern all bolts and nuts before applying
full tightening torque value.
4. Tighten the oil cooler bracket bolt to the
following specified torque.
Symbol Description
T A
B
Intake manifold
Bracket
AF
C Bolt
Specified torque (C):
0.9 ~ 1.1 kgm (9 ~ 11 Nm, 6.51 ~ 7.96 ft.lbs)
DOINC015R11045
R
D

DISASSEMBLY AND REASSEMBLY WCH015SASSY11017
T
AF
R
DOINC015R11049
Removal Steps
1. Map sensor
D
2. Purge solenoid valve

3. Hose clamp
4. Fuel vapor hose 1
5. Non-return valve
6. Fuel vapor hose 2
7. Breather hose 2
8. High tension clamp
9. Breather hose 1
10. Intake manifold
T1 : 1.0 kgm (10 Nm, 7.23 ft.lbs) ±0.1 kgm (1 Nm, 0.72 ft.lbs)


SERVICE POINTS WCH015SPROC11023
HIGH TENSION CLAMP REMOVAL AND

1. Use the high tension clamp plier to release
and install the high tension clamp.
Symbol Description
A High tension clamp pliers
B Arrow marking
DOINC015R11062
2. To release the high tension clamp, make sure

the arrow marking at the high tension clamp
plier is pointing upward and to clamp it, the
arrow marking must be pointing down
wards.
Symbol Description
T A
B
High tension clamp plier
Arrow marking
AF
C Breather hose
D Non-return valve
DOINC015R11063 E Intake manifold
F High tension clamp
FUEL VAPOR HOSE AND BREATHER HOSE

R

Install the fuel breather hose and the vapor hose
to the intake manifold. Ensure the following
D
items are inproperly position as shown in the il-

lustration.
Symbol Description
A Intake manifold
B Breather hose
C Fuel vapor hose
DOINC015R11064
D Non-return valve
E High tension clamp
F Clamp
1. Each hose and non-return valve is marked
with arrows.
2. During installation, please make sure the
hoses and the non-return valve are arranged
according to the arrows marking as shown
CAUTION
Wrongly installed the non-return valve may
cause the engine jerking.

3. Please ensure all the clamp are in it’s position

and secure according to the direction as
CAUTION
Ensure the hoses and the clamps is properly
install to avoid it from damages other parts
in case of car crash.
T
AF
R
D

/ 18 TURBOCHARGER
TURBOCHARGER WCH015SASSY11018
T
AF
R
DOINC015R11052
D
Non-reusable parts
Removal Steps
1. Hose clamps
2. Turbo coolant hose
3. Recirculation pump hose
4. Copper washer
5. Oil feed pipe
7. Lower turbo heatshield
8. Upper turbo heatshield
9. Catalytic converter assy
10. Turbocharger gasket
11. Oil drain pipe
12. Oil drain pipe gasket
13. Turbocharger

TURBOCHARGER / 19
T1 : 0.9 ~ 1.1 kgm (9 ~ 11 Nm, 6.51 ~ 7.96 ft.lbs)

T4 : 3.5 ~ 4.5 kgm (35 ~ 45 Nm, 25.32 ~ 32.55 ft.lbs)
T5 : 1.5 ~ 1.8 kgm (15 ~ 18 Nm, 10.85 ~ 13.02 ft.lbs)
T6 : 0.6 ~ 0.8 kgm (6 ~ 8 Nm, 4.34 ~ 5.79 ft.lbs)
T
AF
R
D

/ 20 TURBOCHARGER
TURBOCHARGER REMOVAL
1. Drain the engine coolant. Refer to Group 014
- Cooling (Pub. No RDCE-09FZ6Y010–00)
2. Loosen the overflow hose clamp, remove the
reserve tank and overflow hose properly.
Symbol Description
A Reserve tank
B Overflow hose
C Clamp
D Radiator assy
3. Remove the air cleaner assy. Refer to page
15/2 .
DOINC015R11010
4. Disconnect the PWM valve connector prop-
T
erly. (Waste gate control connector).
Symbol Description
AF
PWM valve connector (Waste
A
gate control connector).
R
DOINC015R11011
5. Disconnect the E-CRV valve properly. (Boost

D
dump recirculation connector).
Symbol Description
E-CRV valve connector (Boost
A
dump recirculation connector).
DOINC015R11012

TURBOCHARGER / 21
6. Loosen the clamp and remove the turbo

coolant hose from the radiator assy.
Symbol Description
A Turbo coolant hose
B Clamp
C Radiator assy
DOINC015R11013
7. Loosen the clamp and remove the recircula-

tion pump hose assy from coolant feed pipe.
Symbol Description
A Recirculation pump hose assy
B Clamp
T
C Coolant feed pipe
AF
DOINC015R11014
8. Loosen the clamp and remove the zip tube

from the air inlet turbo compressor.
R
Symbol Description
A Zip tube
B Clamp
D
C Air inlet turbo compressor
DOINC015R11015
9. Loosen the clamp and remove the charge air

hot hose from the air outlet turbo com-
pressor.
Symbol Description
A Charge air hot hose
B Clamp
C Air outlet turbo compressor
DOINC015R11016

/ 22 TURBOCHARGER
10. For easier to remove the catalytic converter,

remove the fan shroud assy (4 pieces tapping
screw).
CAUTION:
Do not damage the fin surface of condenser
while remove out the fan shroud from the
radiator assy.
Symbol Description
A Fan shroud
B Tapping screw
DOINC015R11017 C Radiator assy
11. Remove the oil feed pipe assy’s eye bolt (2
pieces) and bolt bracket (1 piece).
Symbol Description
A Oil feed pipe assy
B Eye bolt
T
C Bracket bolt
AF
R
D
DOINC015R11027

TURBOCHARGER / 23
12. Remove the upper and lower heatshield

turbo nuts (4 pieces) and heatshield lower
bolts (2 pieces).
Symbol Description
A Upper heatshield turbo upper
B Nut
C Bolt
D Lower heatshield turbo
Lift-up the vehicle by the lifter.
CAUTION
Before use the lifter, ensure to follow the
lifter procedure first.
T
AF
DOINC015R11028
13. Remove the front exhaust pipe nuts (3

pieces).
R
Symbol Description
A Catalytic converter
B Nut
D
C Front exhaust pipe

D Gasket
DOINC015R11020
14. Remove the catalytic converter bracket bolts

(4 pieces).
Symbol Description
A Bolt
B Bracket
Lift-down the vehicle by the lifter.
CAUTION
DOINC015R11021

/ 24 TURBOCHARGER
15. Remove the oxygen sensor by using the spe-

cial tool (MD998770).
Symbol Description
A Oxygen sensor
B Special tool (MD998770)
C Catalytic converter
DOINC015R11022
16. Remove the catalytic converter nuts (3 pieces)

and remove the catalytic converter from
downward properly.
Symbol Description
A Turbocharger assy
B Nut
T Lift-up the vehicle by the lifter.

CAUTION
AF
DOINC015R11023
17. Use an allen key to remove the oil drain pipe

screws (2 pieces) properly.
R
Symbol Description
A Oil drain pipe
B Screw
D
C Allen key
DOINC015R11024
18. Remove the turbocharger nuts (3 pieces).
Symbol Description
A Nut
B Exhaust manifold
CAUTION
DOINC015R11025

TURBOCHARGER / 25
19. Remove the turbocharger assy properly.
DOINC015R11026

WCH015SPROC11025
TURBOCHARGER INSTALLATION
1. Insert the gasket to the turbocharger assy
studs, ensure the gasket serial number is fa-
cing to the turbocharger and then install the
T turbocharger assy to the exhaust manifold

AF
Symbol Description
A Gasket
B Stud
C Turbocharger assy
D Exhaust manifold
R
E Gasket serial number

CAUTION
D

DOINC015R11033
2. Tighten the turbocharger nuts (3 pieces).
Symbol Description
A Nut
B Exhaust manifold
Specified torque (A):
2.5 kgm (25 Nm, 18.08 ft.lbs) ±0.5 kgm (5
Nm, 3.62 ft.lbs)
DOINC015R11025

/ 26 TURBOCHARGER
3. Fit the gasket to the oil drain pipe and use

an allen key to tighten the screws (2 pieces)
properly as shown in the illustration.
Symbol Description
A Oil drain pipe
B Screw
C Gasket
D Allen key
Specified torque (B):
0.9 ~ 1.1 kgm (9 ~ 11 Nm, 6.51 ~ 7.96 ft.lbs)

CAUTION
T
AF
DOINC015R11030
4. Insert the gasket to the turbocharger assy

studs and fit the catalytic converter.
R
Symbol Description
A Gasket
B Turbocharger assy stud
D
DOINC015R11029
5. Tighten the catalytic converter nuts (3 pieces)

properly.
Symbol Description
A Turbocharger assy
B Nut
2.8 kgm (28 Nm, 20.25 ft.lbs) ±0.2 kgm (2
Nm, 1.45 ft.lbs)
DOINC015R11023

TURBOCHARGER / 27
6. Tighten the oxygen sensor by using the spe-

cial tool (MD998770).
Symbol Description
A Oxygen sensor
3.5 ~ 4.5 kgm (35 ~ 45 Nm, 25.32 ~ 32.55
ft.lbs)
DOINC015R11022
CAUTION
7. Tighten the catalytic converter bracket bolts
(4 pieces) properly.
Symbol Description
T A
B
Bolt
Bracket
AF
2.4 kgm (24 Nm, 17.36 ft.lbs) ±0.2 kgm (2
Nm, 1.45 ft.lbs)
DOINC015R11021
R
8. Insert the gasket to the catalytic converter

studs and tighten the front exhaust pipe nuts
(3 pieces).
D
Symbol Description
A Catalytic converter
B Front exhaust pipe
C Nut
D Gasket
3.3 ~ 4.9 kgm (33 ~ 49 Nm, 23.87 ~ 35.44
DOINC015R11020 ft.lbs)

CAUTION

/ 28 TURBOCHARGER
9. Tighten the upper and lower heatshield

turbo nuts (4 pieces) and heatshield lower
bolts (2 pieces).
Symbol Description
A Upper heatshield turbo
B Nut
C Bolt
D Lower heatshield turbo
Specified torque (B) and (C):
0.9 ~ 1.1 kgm (9 ~ 11 Nm, 6.51 ~ 7.96 ft.lbs)
T
AF
DOINC015R11028
10. Before tighten the oil feed pipe assy, ensure

to insert new cooper washer to the eye bolt,
fit it to the oil feed pipe assy and insert an-
R
other new cooper washer to the end of the

eye bolt and then tighten the bracket bolt.
Symbol Description
D
A Oil feed pipe assy

B Eye bolt
C Bracket bolt
CAUTION:
The cooper washer is non-reusable part.
1.5 ~ 1.8 kgm (15 ~ 18 Nm, 10.85 ~ 13.02
ft.lbs)

0.6 ~ 0.8 kgm (6 ~ 8 Nm, 4.34 ~ 5.79 ft.lbs)
DOINC015R11027

TURBOCHARGER / 29
11. Install the fan shroud to the radiator assy

carefully and tighten the fan shroud tapping
screws (4 pieces).
CAUTION:
Do not damage the fin surface of condenser
while removing out the fan shroud from the
radiator assy.
Symbol Description
A Fan shroud
B Tapping screw
DOINC015R11017 C Radiator assy
0.4 ~ 0.55 kgm (4 ~ 5.5 Nm, 2.89 ~ 3.98 ft.lbs)
12. Fit the hot air charge hose to the air outlet
turbo compressor and tighten the clamp.
Symbol Description
T A
B
C
Hot air charge hose
Clamp
Air outlet turbo compressor
AF
0.3 ~ 0.4 kgm (3 ~ 4 Nm, 2.17 ~ 2.89 ft.lbs)
DOINC015R11016
R
13. Fit the zip tube to the air inlet turbo com-
pressor and tighten the clamp.
Symbol Description
D
A Zip tube
B Clamp
C Air inlet turbo compressor
<0.3 kgm (3 Nm, 2.17 ft.lbs)
DOINC015R11015

/ 30 TURBOCHARGER
14. Fit the recirculation pump hose assy to

coolant feed pipe and clamp the hose prop-
erly.
Symbol Description
A Recirculation pump hose assy
B Clamp
C Coolant feed pipe
DOINC015R11014
15. Fit the turbocharger coolant hose to the ra-

diator assy and clamp the hose properly.
Symbol Description
A Turbocharger coolant hose
B Clamp
T
C Radiator assy
AF
DOINC015R11013
16. Connect the E-CRV valve connector properly.

(Boost dump recirculation connector)
R
Symbol Description
E-CRV valve connector (Boost
A
dump recirculation connector)
D
DOINC015R11012
17. Connect the PWM valve connector properly.

(Waste gate control connector)
Symbol Description
PWM valve connector (Waste
A
gate control connector)
18. Install the air cleaner assy. Refer to page
15/2 .
DOINC015R11011

TURBOCHARGER / 31
19. Install the reserve tank and fit the overflow

hose to the radiator assy. Clamp the hose
properly.
Symbol Description
A Reserve tank
B Overflow hose
C Clamp
D Radiator assy
20. Fill the engine coolant. Refer to Group 014
- Cooling (Pub. No RDCE-09FZ6Y010–00)
DOINC015R11010
NOTE:
Incorrect use of a turbocharger or changes to
the turbocharger may lead to damage. Before
install the turbocharger on the exhaust manifold,
check the following items;
(1) Rotate the wheels by the hand, make sure
there is no interference between the wheels
and housing.
T (2) Make sure the air filter is clean and in good

condition.
(3) Check there is no foreign things in the tur-
AF
bine and compressor inlet pipe.
(4) Check the cleanliness of the oil inlet and
outlet pipes, and no contortion or plug.
(5) Check the oil filter is clean and in good con-
dition. Fill the filter with clean oil.
(6) Check the cleanliness of the oil. Replacement
R
of oil should be in hot condition.

(7) Forbid to gelatinize on the oil inlet gasket
and outlet flanges.
(8) Check the oil level in the crankcase.
D
(9) Fill with the appointed oil.

/ 32 TURBOCHARGER
T
AF
R
DOINC015R11048
Non-reusable parts
D
Pre-removal and post-installation operation.

• Turbo removal and installation refer to page 15/18 .
Removal Steps
1. PWM valve (Waste Gate Control valve)
2. Control pressure hose
3. Atmospheric pressure hose
4. E-CRV valve (Boost Dump Recirculation valve)
5. Boost pressure hose
6. High tension clamp
7. Turbocharger
8. Stud

TURBOCHARGER / 33
ASSEMBLY AND REASSEMBLY SERVICE

POINTS WCH015SPROC11026
HIGH TENSION CLAMP PRESSURE HOSE

1. Use the high tension clamp pincer to remove
the high tension clamp pressure hose.
Symbol Description
A High tension clamp pincer
DOINC015R11065
2. Remove the high tension clamp from the

control pressure hose, atmospheric pressure
hose and boost pressure hose by using high
tension clamp pincer to cut off the omega
head shaped on high tension clamp easier.
Symbol Description
T A
B
High tension clamp pincer
High tension clamp
AF
C Omega head shaped
DOINC015R11066
HIGH TENSION CLAMP PRESSURE HOSE

R
1. Use the high tension clamp pincer to crimp

the high tension clamp pressure hose.
Symbol Description
D
A High tension clamp pincer
DOINC015R11065

/ 34 TURBOCHARGER
2. Insert the high tension clamp to the control

pressure hose, atmospheric pressure hose and
boost pressure hose. Before crimp the high
tension, make sure the crimping points is
parallel to the level mark on the pressure
hose.
Symbol Description
A High tension clamp pincers
High tension clamp crimping
B
points
C Level mark
D Pressure hose
CAUTION
Do not apply excessive force to crimp the high
tension clamp. It may cause damage to the
clamp. Ensure the high tension clamp is properly
fix to the hose.
T
AF
DOINC015R11070
PWM (WASTE GATE CONTROL) VALVE AND

E-CRV (BOOST DUMP RECIRCULATION) VALVE
R

1. Use torx type tool to remove 2 pieces bolts
PWM (Waste Gate Control) valve.
D
Symbol Description
A PWM (Waste Gate Control) valve
B Torx type tool
C Bolt
DOINC015R11067
2. Use torx type tool to remove 3 pieces bolts

E-CRV (Boost Dump Recirculation) valve.
Symbol Description
E-CRV (Boost Dump Recircula-
A
tion) valve
B Torx type tool
C Bolt
DOINC015R11068

TURBOCHARGER / 35
PWM (WASTE GATE CONTROL) VALVE AND

E-CRV (BOOST DUMP RECIRCULATION) VALVE
1. Use torx type tool to install 2 pieces bolts
PWM (Waste Gate Control) valve.
Symbol Description
A PWM (Waste Gate Control) valve
B Torx type tool
C Bolt
DOINC015R11067
1.0 kgm (10 Nm, 7.23 ft.lbs)
±0.1 kgm (1 Nm, 0.72 ft.lbs)
2. While installing the E-CRV (Boost Dump Re-

circulation) valve on the turbocharger, make
sure the stud marks on both sides of the
parallel.
T Symbol
A
Description
tion) valve
AF
B Stud marks
R
D
DOINC015R11071

/ 36 TURBOCHARGER
3. Use torx type tool to install 3 pieces bolts E-

CRV (Boost Dump Recirculation) valve.
Symbol Description
A
tion) valve
B Torx type tool
C Bolt
1.0 kgm (10 Nm, 7.23 ft.lbs)
±0.1 kgm (1 Nm, 0.72 ft.lbs)
DOINC015R11068
TURBOCHARGER STUD REMOVAL

1. Install 2 pieces nut pair in sequence on a
turbocharger stud and use the open end
spanner and the ring spanner to tie up tightly
in a clockwise direction as shown in illustra-
tion
T Symbol
A
Description
Turbocharger
AF
B Stud
C Nut
D Open end spanner
E Ring spanner
R
D
DOINC015R11072

TURBOCHARGER / 37
2. Use the open end spanner to turn the lower

nut in anti-clockwise direction to loose and
remove the turbocharger stud as shown in
illustration.
Symbol Description
A Turbocharger
B Open end spanner
C Lower Nut
D Stud
T
AF
DOINC015R11073
TURBOCHARGER STUD INSTALLATION

1. Install 2 pieces nut pair in sequence to the
R
most long tread of the new stud and install

it to the turbocharger by part which was ap-
ply with lock-tied . Use the open end spanner
D
and the ring spanner to tie up tightly in a

clockwise direction as shown in illustration.
Symbol Description
A Stud
B Lock-tied
C Nut
D Turbocharger
E Open end spanner
F Ring spanner
1.5 kgm (15 Nm, 10.85 ft.lbs)
±0.1 kgm (1 Nm, 0.72 ft.lbs)
DOINC015R11074

/ 38 SPECIAL TOOL
TOOL
MB990784 Ornament remover Removal of bumper
mounting clips
(front and rear) and
door mirror control
switch
DOIIC051R9001
T
AF
R
D

INTERCOOLER / 39
INTERCOOLER WCH015SASSY11020
T
AF
R
D
DOIQC015R11008

/ 40 INTERCOOLER
• Front bumper removal and installation (Refer to MODULE 1.0, GROUP 52A)
Intercooler removal steps
1. Splash shield (LH)
2. Under cover (LH)
3. Clip
4. Air guide assy
5. Outlet hose
6. Inlet hose
7. Upper bracket
8. Lower bracket
9. Intercooler tank
10. Charge air duct assy
T1 : 0.75 - 0.15 kgm (7.5 - 1.5 Nm, 5.42 - 1.08 ft.lbs)
T3 : 0.3 - 0.35 kgm (3 - 3.5 Nm, 2.17 - 2.53 ft.lbs)
T4 : 0.5 - 0.55 kgm (5 - 5.5 Nm, 3.62 - 3.98 ft.lbs)
T
AF
R
D

INTERCOOLER / 41
INTERCOOLER REMOVAL
1. Remove front bumper (Refer to group 051-
Front bumper).
2. Use the special tool MB990784 to remove the
harness clip.
Symbol Description
A Harness clip
DOIQC015R11009
3. Remove the front fog lamp harness connect-

or from the air guide assy.
T Symbol
A
Description
Connector
AF
B Air guide assy
R
DOIQC015R11010
4. Use the special tool MB990784 to pull up the

center lock pin of clip from the air guide assy.
D
Symbol Description
A Clip
B Air guide assy
DOIQC015R11011

/ 42 INTERCOOLER
5. Remove the air guide assy from the intercool-

er tank.
DOIQC015R11012
6. Remove the intercooler lower bracket nuts

(2 pieces).
Symbol Description
C Nut
D Lower bracket
T
AF
DOIGC014R11027
7. Remove the lower bracket.

R
D
DOIGC014R11029
8. Release the inlet hose clamp.
Symbol Description
E Inlet hose
F Clamp
G Intercooler tank
DOIGC014R11030

INTERCOOLER / 43
9. Release the outlet hose clamp and remove

the intercooler tank.
Symbol Description
H Outlet hose
I Clamp
J Intercooler tank
DOIGC014R11031
10. Remove the intercooler tank.
T
AF
DOIGC014R11032
11. Release the outlet hose clamp to remove the

hose from charge air duct assy.
R
Symbol Description
K Charge air duct assy
L Clamp
D
M Outlet hose
DOIGC014R11033
12. Release the inlet hose clamp to remove the

hose from air outlet turbo compressor.
Symbol Description
N Air outlet turbo compressor
O Clamp
P Inlet hose
DOIGC014R11035

/ 44 INTERCOOLER
13. Disconnect the map sensor 2 connector from

charge air duct assy.
Symbol Description
Q Connector
R Map sensor 2
S Charge air duct assy
DOIQC015R11013
14. Remove charge air duct assy bolt.
Symbol Description
T Bolt
U Charge air duct assy
T
AF
DOIQC015R11014
15. Release the charge air duct assy clamp.
Symbol Description
R
V Clamp
W Charge air duct assy
D
DOIQC015R11015
16. Remove the charge air duct assy from the

throttle body.
DOIGC014R11049

EXHAUST MANIFOLD / 45
EXHAUST MANIFOLD WCH015SASSY11021
T
AF
R
DOINC015R11051
D
Pre-removal and post-installation

Turbo removal and installation refer to 15/18 .
Removal Steps
1. Turbo heatshield bracket.
2. Exhaust manifold heatshield
3. Support brace
4. Exhaust manifold
5. Exhaust manifold gasket
T1 : 2.2 ~ 2.6 kgm (22 ~ 26 Nm, 15.91 ~ 18.81 ft.lbs)
T5 : Tightening torque procedure for Exhaust Manifold:
Step Torque Bolt Numbers
2.8 kgm (28 Nm, 20.25 ft.lbs) ±0.2 Bolt no. 1 to bolt no. 8 (In ascending or-
A
kgm (2 Nm, 1.45 ft.lbs) der)
2.8 kgm (28 Nm, 20.25 ft.lbs) ±0.2
B

/ 46 EXHAUST MANIFOLD
REMOVE EXHAUST MANIFOLD

1. Remove the turbocharger assy. Refer to page
15/20 .
2. Remove the turbocharger heatshield bracket
bolts (2 pieces).
Symbol Description
Turbocharger heatshield brack-
A
et.
B Bolt
DOINC015R11059
3. Remove the exhaust manifold heat shield
T
bolts ( 4 pieces).
Symbol Description
AF
A Exhaust manifold
B Heat shield
C Bolt
R
DOINC015R11034
4. Remove the exhaust manifold support brace

D
bolt (1 piece) and nut (1 piece).
Symbol Description
A Exhaust manifold
B Support brace
C Bolt
D Nut
DOINC015R11035

5. Remove the exhaust manifold nuts - 8 pieces.
Symbol Description
A Exhaust manifold
B Nut
DOINC015R11036
6. Remove the exhaust manifold properly.
Symbol Description
A Gasket
B Stud
C Exhaust manifold
T
AF
DOINC015R11038
7. Remove the exhaust manifold gasket prop-

erly.
R
Symbol Description
A Gasket
B Stud
D
DOINC015R11037

WCH015SPROC11029
EXHAUST MANIFOLD INSTALLATION

1. Fix the exhaust manifold gasket to the cylin-
der head studs properly.
Symbol Description
A Gasket
B Stud
DOINC015R11037

2. Install the exhaust manifold to the cylinder

head studs properly. Then tighten temporar-
ily the exhaust manifold nuts (8 pieces) by
hand.
Symbol Description
A Gasket
B Stud
C Exhaust manifold
DOINC015R11038
3. Tighten the exhaust manifold nuts accord-

ingly in order sequence number as shown in
the illustration. Then tighten the nuts to the
specified torque.
Tightening torque procedure for Exhaust
manifold (T1) :
T Step Torque
2.8 kgm (28
Nm, 20.25
Bolt Numbers
AF
A ft.lbs) ± 0.2
kgm (2 Nm, Bolt no. 1 to
1.45 ft.lbs) Bolt no. 8
2.8 kgm (28 (In ascending
Nm, 20.25 order)
B ft.lbs) ± 0.2
R
kgm (2 Nm,
1.45 ft.lbs)
Symbol Description
D
C Exhaust manifold
NOTE
Fasten all the nuts and check the tightening
torque.
DOINC015R11039
4. Install the exhaust manifold support brace

then tighten the bolt (1 piece) and nut (1
piece).
Symbol Description
A Exhaust manifold
B Support brace
C Bolt
D Nut
Specified torque (C) :
2.5 kgm (25 Nm, 18.08 ft.lbs) ±0.5 kgm (5 Nm,
DOINC015R11035 3.62 ft.lbs)

Specified torque (D) :

1.45 ft.lbs)
5. Install the exhaust manifold heat shield bolts

(4 pieces).
Symbol Description
A Exhaust manifold
B Heat shield
C Bolt
Specified torque (C) :
1.45 ft.lbs)
DOINC015R11034
6. Install the turbocharger heatshield bracket

bolts (2 pieces).
T Symbol
A
Description
Turbocharger heatshield brack-
et.
AF
B Bolt
Specified torque (B) :
2.2 ~ 2.6 kgm (22 ~ 26 Nm, 15.91 ~ 18.81
ft.lbs)
R
DOINC015R11059
D

/ 50 EXHAUST PIPE AND MAIN MUFFLER
EXHAUST PIPE AND MAIN MUFFLER WCH015SASSY11022
T
AF
R
D
DOIQC015R11007

EXHAUST PIPE AND MAIN MUFFLER / 51
Main muffler sub assy removal steps

1. Bolts
2. Gasket
3. Main muffler
4. Hanger
Front exhaust pipe sub assy removal steps
5. Nuts
6. Gasket
7. * Rear oxygen sensor
8. Hanger
9. Front exhaust pipe
Heat protector panel removal steps
10. Bolts
11. Nuts
12. Front floor heat protector panel
13. Rear floor heat protector panel
T1 : 4.0 ~ 5.0 kgm (40 ~ 50 Nm, 28.93 ~ 36.16 ft.lbs)
T2 : 0.4 ~ 0.6 kgm (4 ~ 6 Nm, 2.89 ~ 4.34 ft.lbs)
* If iffited
T
AF
R
D

NOTE
T
AF
R
D

INTAKE AND EXHAUST <IAFM+> 15
Content /1
15 INTAKE AND EXHAUST <IAFM+>

INTAKE MANIFOLD AND VACUUM TANK ASSY ................................ 15/2
CONNECTOR LOCATION ........................................................... 15/2
INTAKE MANIFOLD ................................................................... 15/5

DISCONNECT CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15/5
EXHAUST MANIFOLD ................................................................ 15/8

EXHAUST PIPE AND MAIN MUFFLER .............................................. 15/14

T
AF
R
D

/2 INTAKE MANIFOLD AND VACUUM TANK ASSY
INTAKE MANIFOLD AND VACUUM TANK ASSY WCH015SASSY12001
CONNECTOR LOCATION
T
AF
R
DOIMC015R07011
D
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 — Vacuum actuator
B — T-Map sensor
C — Intake engine connector
D — Cam sensor
E — Soleniod valve
F — Throttle body actuator
G — Crank sensor
H — Injector harness
I — Hose vacuum actuator
J — Hose solenoid
K — Hose NRV to Throttle body

INTAKE MANIFOLD AND VACUUM TANK ASSY /3
T
AF
R
D
DOIMC015R07002

/4 INTAKE MANIFOLD AND VACUUM TANK ASSY
Non-reusable parts
• Fuel discharge prevention (GROUP 13–Fuel)
• Air cleaner removal (GROUP 15–Intake & Exhaust)
• Throttle body removal (GROUP 13–Fuel)
• Throttle body installation (GROUP 13 Fuel)
• Air cleaner installation (GROUP 15 Intake & Exhaust)
• All hoses need to be inserted properly to avoid leakage.
Removal steps
1. Control wiring harness
2. Fuel rail module
3. Hose pressure regulator
4. High-pressure fuel hose connection
5. Fuel return hose connection
6. Throttle body connector
7. Throttle body
8. Throttle body gasket
9.
10.
11.
Intake manifold
Gasket intake manifold
Intake manifold bracket stay
T
AF
12.Vacuum actuator
13.Sensor-mass air temperature (T-Map)
14.Vacuum tank
15.Purge solenoid
R
D

INTAKE MANIFOLD /5
INTAKE MANIFOLD WCH015SPROC12001

NEGATIVE BATTERY CABLE FROM THE
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
DISCONNECT CONNECTOR
Disconnect the harness connector at engine room
T
(Refer to 15/7 ).
HIGH-PRESSURE AND RETURN FUEL HOSE

AF
REMOVAL
1. When remove the high-pressure fuel hose
(A) from the delivery pipe (B) press the con-
nector and release it from the delivery pipe,
being careful not to damage the connector
and hose line.
R
Symbol Description
Quick connector type; press
A forward the connector and
D
DOIGC015R08001 pull
B Delivery pipe
CAUTION
Quick connector must be inserted securely
to the mating pipe until the retainer holds
the pipe spool securely, check the connection
by pulling the connector gently in direction
B

/6 INTAKE MANIFOLD
2. When removing the return fuel hose (C) from

the delivery pipe (D), press the connector and
release it from the delivery pipe. Be careful
not to damage the connector and hose line.
Symbol Description
Quick connector type; press
C forward the connector and
pull
D Delivery pipe
CAUTION
DOIGC015R08002
Be careful not to let any engine oil get into
the fuel rail.
FUEL RAIL PIPE, INJECTOR AND PRESSURE

REGULATOR REMOVAL
1. Remove the delivery pipe with the injectors.
2. Refer to Group 13A - Service point for remov-
al injector
T CAUTION
When removing the delivery pipe,please do not
drop the injector
AF
DOIMC015R07029
INTAKE AIR FUEL MODULE (IAFM) REMOVAL

R
1. Remove bolt upper bracket intake manifold.
Symbol Description
A Bolt upper bracket
D
B Intake manifold
DOIMC015R07012
2. Remove bolt flange and nut intake manifold

from the cylinder head.
Symbol Description
C Bolt cylinder head
D Intake manifold
DOIMC015R07015

INTAKE MANIFOLD /7
3. Remove intake manifold slowly and carefully.
DOIMC015L08008
VACUUM ACTUATOR REMOVAL

1. Remove bolt vacuum actuator at intake
manifold.
2. When removing vacuum actuator,push the
lock pin actuator from intake manifold with
suitable tool as shown in the illustration.
T Symbol
A
Description
Map sensor
AF
B Vacuum actuator
C Bolt
D suitable tool
E Clutch
F Nut
R
D
DOIMC015L08002

/8 EXHAUST MANIFOLD
EXHAUST MANIFOLD WCH015SASSY12002
T
AF
R
DOIMC015R07005
D
— 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. Oxygen sensor
2. Heatshield
3. Lifting eye
4. Catalytic converter bracket
5. Catalytic converter
6. Converter gasket
7. Exhaust manifold
8. Exhaust manifold gasket
T1 : 3.43 - 4.41 kgm (34.3 - 44.1 Nm, 24.81 - 31.9 ft.lbs)
T2 : 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)
T3 : 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
Tightening torque procedure for Exhaust manifold (T4) :

EXHAUST MANIFOLD /9
Step Torque Bolt numbers

2.8 kgm (28 Nm, 20.25 ft.lbs) ± 0.2 kgm (2
A
Nm, 1.45 ft.lbs) Bolt no. 1 to Bolt no. 8
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2 (In ascending order)
B
Nm, 1.45 ft.lbs)
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2 Bolt no. 3 & Bolt no. 6
C
Nm, 1.45 ft.lbs) (If required only)
T
AF
R
D

OXYGEN SENSOR REMOVAL

By using special tool, remove the oxygen sensor.
Symbol Description
A Special tool MD998770
DOIGC015R03008
REMOVE EXHAUST MANIFOLD

1. After removing the exhaust manifold cover
and catalytic converter nut
Symbol Description
A Nut
T
AF
DOIMC015R07006
2. Make sure tie the catalytic converter at latch

assy hood using cord
R
Symbol Description
Tie the cord at the latch assy
B
hood
D
C Latch
DOIMC015R07007

3. Separate the catalytic converter and exhaust

system from the exhaust manifold and hang
independently.
Symbol Description
Tie the cord at the latch assy
B
hood
C Latch
D Exhaust manifold
T
AF
DOIMC015R07008

WCH015SPROC12003
R

1. Install gasket to cylinder head and insert
nylon spacer (Locator) to cylinder head stud
D
right side and left end. (Note: insert nylon

spacer on 2 stud only).
Symbol Description
A Gasket
DOIGC015R03026
2. Install exhaust manifold to cylinder head stud

and tighten the nut.
Tightening the nuts according to the se-
quence as shown in the table below, tighten
nuts to specified torque.
Tightening torque procedure for Exhaust
manifold (T1) :
DOIHC015R04006

Step Torque Bolt numbers

2.8 kgm (28 Nm,
20.25 ft.lbs) ± 0.2
A
kgm (2 Nm, 1.45 Bolt no. 1 to
ft.lbs) Bolt no. 8
2.5 kgm (25 Nm, (In ascending
18.08 ft.lbs) ± 0.2 order)
B
kgm (2 Nm, 1.45
ft.lbs)
2.5 kgm (25 Nm, Bolt no. 3 &
18.08 ft.lbs) ± 0.2 Bolt no. 6
C
kgm (2 Nm, 1.45 (If required
ft.lbs) only)
Symbol Description
B Exhaust manifold
3. Install catalytic converter to exhaust manifold
and tighten the nut to the specified torque.
Symbol Description
T C
D
Exhaust manifold
Catalytic converter
AF
4.8 - 5.2 kgm (48 - 52 Nm, 34.72
T2
- 37.61 ft.lbs)
DOIMC015R07027
R
4. Install heatshield to exhaust manifold and

tighten bolt to the specified torque.
D
Symbol Description
E Heatshield
2.2-2.6 kgm (22-26 Nm, 15.91-
T3
18.81 ft.lbs)
DOIGC015R03029

5. Install oxygen sensor to the exhaust mani-

fold.
Symbol Description
F Exhaust manifold
G Oxygen sensor
DOIGC015R03030
6. Install the oxygen sensor using the special

tool to tighten the sensor.
Symbol Description
H Special tool MD998770
3.4-4.4 kgm (34-44 Nm, 24.59-
T4
31.83 ft.lbs)
T
AF
DOIGC015R03031
R
D

EXHAUST PIPE AND MAIN MUFFLER WCH015SASSY12003
T
AF
R
D
DOIQC015R12001

EXHAUST PIPE AND MAIN MUFFLER / 15
Main muffler sub assy removal steps

1. Bolts
2. Gasket
3. Main muffler
4. Hanger
Front exhaust pipe sub assy removal steps
5. Nuts
6. Gasket
7. Rear oxygen sensor
8. Hanger
Heat protector panel removal steps
10. Bolts
11. Nuts
T1 : 4.0 ~ 5.0 kgm (40 ~ 50 Nm, 28.93 ~ 36.16 ft.lbs)
T2 : 0.4 ~ 0.6 kgm (4 ~ 6 Nm, 2.89 ~ 4.34 ft.lbs)
T
AF
R
D

NOTE
T
AF
R
D

ENGINE ELECTRICAL 16
Content /1
16 ENGINE ELECTRICAL
CHARGING SYSTEM .................................................................. 16/4
GENERAL INFORMATION .......................................................... 16/4
OPERATION .......................................................................... 16/4
SYSTEM DIAGRAM .................................................................. 16/4
ALTERNATOR SPECIFICATIONS <CFE & IAFM+> ............................... 16/5
SERVICE SPECIFICATIONS .......................................................... 16/5
TORQUE SPECIFICATIONS ......................................................... 16/6
SPECIAL TOOL ....................................................................... 16/6
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST .......................... 16/7
OUTPUT CURRENT TEST ........................................................... 16/9
REGULATED VOLTAGE TEST ....................................................... 16/11
VOLTAGE REGULATION STANDARD TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/12
WAVEFORM CHECK USING AN ANALYZER .................................... 16/13
MEASUREMENT METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/13
STANDARD WAVEFORM (OBSERVATION CONDITIONS) .................... 16/13
EXAMPLES OF ABNORMAL WAVEFORMS ..................................... 16/14
ALTERNATOR ........................................................................ 16/17
REMOVAL AND INSTALLATION <CFE> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/17
REMOVAL AND INSTALLATION <IAFM+> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/18
T
DISASSEMBLY AND REASSEMBLY <CFE & IAFM+> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL SERVICE POINT <CFE> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL SERVICE POINT <IAFM+> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16/19
16/20
16/21
AF
ALTERNATOR DISASSEMBLY SERVICE POINTS <CFE & IAFM+> ............ 16/24
REASSEMBLY SERVICE POINT <CFE & IAFM+> ................................ 16/25
INSPECTION <CFE & IAFM+> ...................................................... 16/25
ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/25
STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/26
RECTIFIERS ........................................................................... 16/26
BRUSH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/27
ALTERNATOR ........................................................................ 16/28
R
FEAD BELT ROUTE <CFE & IAFM+> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/28

FEAD BELT DRIVE REMOVAL SERVICE POINTS <CFE & IAFM+> ............ 16/29
FEAD BELT DRIVE INSTALLATION SERVICE POINTS <CFE & IAFM+> ...... 16/29
D
STARTING SYSTEM .................................................................... 16/31

SYSTEM DIAGRAM .................................................................. 16/32
SPECIFICATIONS <CFE & IAFM+> ................................................. 16/32
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/33
STARTER MOTOR .................................................................... 16/34
REMOVAL AND INSTALLATION <CFE & IAFM+> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/34
REMOVAL SERVICE POINT <CFE> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/35
REMOVAL SERVICE POINT <IAFM+> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/36
STARTER MOTOR REMOVAL <CFE & IAFM+> ................................. 16/37
TERMINAL MAGNETIC SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/37
PINION GAP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/37
MAGNETIC SWITCH PULL-IN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/38
MAGNETIC SWITCH HOLD-IN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/39
FREE RUNNING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/39
MAGNETIC SWITCH RETURN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/40
STARTER MOTOR <CFE & IAFM+> ............................................... 16/41
DISASSEMBLY AND REASSEMBLY ..................................................... 16/41
STARTER MOTOR DISASSEMBLY SERVICE POINTS <CFE & IAFM+> ....... 16/42
STARTER MOTOR PARTS CLEANING <CFE & IAFM+> ........................ 16/42
STARTER MOTOR REASSEMBLY SERVICE POINTS <CFE & IAFM+> ........ 16/43
INSPECTION <CFE & IAFM+> ...................................................... 16/43

/2 Content
COMMUTATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/43
FIELD COIL OPEN-CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/44
FIELD COIL GROUND TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/44
BRUSH HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/45
OVERRUNNING CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/45
FRONT AND REAR BRACKET BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/45
BRUSH AND SPRING REPLACEMENT <CFE & IAFM+> ........................ 16/45
ARMATURE TEST <CFE & IAFM+> ............................................... 16/46
ARMATURE SHORT-CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/46
ARMATURE COIL EARTH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/46
ARMATURE COIL OPEN-CIRCUIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/47
IGNITION SYSTEM .................................................................... 16/47

IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/47
SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/48
IGNITION COIL <CFE & IAFM+> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/48
SPARK PLUG <CFE> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/49
SPARK PLUG <IAFM+> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/49
REMOVAL AND INSTALLATION <CFE> .......................................... 16/50
REMOVAL AND INSTALLATION <IAFM+> ...................................... 16/51
ON-VEHICLE SERVICE ...............................................................
T
SPARK PLUG CHECK AND CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION ..........................................................................
16/52
16/52
16/53
AF
IGNITION COIL CHECK <CFE & IAFM+> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/53
WAVEFORM CHECK USING V.M.I OSCILLOSCOPE ............................ 16/53
MEASUREMENT METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/53
STANDARD WAVEFORM OBSERVATION CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/53
WAVEFORM OBSERVATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/54
EXAMPLES OF ABNORMAL WAVEFORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/55
EXAMPLE OF NORMAL WAVEFORM ............................................ 16/57
R
DETONATION/KNOCK SENSOR ..................................................... 16/60

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16/60
D
DETONATION / KNOCK SENSOR ................................................... 16/61


Content /3
NOTE
T
AF
R
D

/4 CHARGING SYSTEM
CHARGING SYSTEM WCH016GINFO11001
GENERAL INFORMATION
The charging system uses the alternator output to keep the battery charged at a constant level under
various electrical loads.
OPERATION
Symbol Description
A Voltage
B Time
T1 Approximately 14.4 V ±0.3 V
Rotation of the excited field coil generates AC
voltage in the stator.
This alternating current is rectified through di-
odes to DC voltage having a waveform shown
in the illustration. The average output voltage
DOINC016R11001 fluctuates slightly with the alternator load con-
dition.
SYSTEM DIAGRAM
T
When the ignition switch is turn on, current flows in the field coil and initial excitations of the field
coil occurs.
AF
When the stator coil begins to generate power after the engine is started, the field coil is excited by
the output current of the stator coil.
The alternator output voltage rises as the field current increase and it falls as the field current speed
decreases. When the battery voltage reaches a regulated voltage of approximately14.4 V, the field
current is cut off. When the battery voltage drops below the regulated voltage, the voltage regulator
regulates the output voltage to a constant level by controlling the field current.
R
In addition, when the field current is constant, the alternator output voltage rises as the engine speed
increases.
D

CHARGING SYSTEM /5
T
AF
DOINC016R09001
R
S4PH: 1.6 L
Symbol Description
D
B Battery
C Voltage regulator
D Field coil
E Stator coil
ALTERNATOR SPECIFICATIONS <CFE & IAFM+> WCH016SPECS11001
Type Battery voltage sensing
Rated output V/A 12 V/90 A
Voltage regulator Electric built-in-type
Rating Continuous
SERVICE SPECIFICATIONS
Regulator preference (Set Volt) 14.4 V ±0.3 V
Speed in use 1000 rpm ~ 18000 rpm
Output performance guarantee (30 °C (86 °F))
Assy alternator 90 A

/6 CHARGING SYSTEM
Output current (A)

Voltage (V) Speed (rpm)
Cold Hot
1300 rpm — 15 min
13.5 V 2500 rpm — 65 min
5000 rpm — 87 min
Temperature stability speed 5000 rpm
Alternator
Brush replacement When beyond wear limit line
Rotor coil resistance 3Ω
TORQUE SPECIFICATIONS
Items Value
Alternator mounting bolt 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Alternator pivot bolt nut 3.3-3.7 kgm (33-37 Nm, 23.87-26.76 ft.lbs)
SPECIAL TOOL
T
WCH016STOOL11001

AF
Installation and removal
EZT 0040 Adapter of overrunning alternat-
or pulley.
DOINC016R11002
R
D

CHARGING SYSTEM /7
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST WCH016SPROC11001
T
AF
R
DOINC016R11003
Symbol Description
A Alternator
D
B Terminal B
C Voltmeter
D Ammeter
E Battery
This test determines whether the wiring from the alternator “B” terminal to the battery (+) terminal
(including the fusible line) is in a good condition or not.
1. Always be sure to check the following before the test:
• Alternator installation.
• Alternator fead belt tension (Refer to 16/17 ).
• Fusible link.
• Abnormal noise from the alternator while the engine is running.
2. Turn off the ignition switch.
3. Disconnected the negative battery cable.
4. Disconnect the alternator output wire from the alternator “B” terminal and connect a DC test
ammeter with a range of 0-100 A in series between the “B” terminal and the disconnected output
wire (connect the (+) lead of the ammeter to the “B” terminal, and then connect the (-) lead of
the ammeter to the disconnected output wire.)

/8 CHARGING SYSTEM
NOTE
An inductive-type ammeter which enable measurements to be taken without disconnecting the
alternator output wire shown be recommended. Using this equipment will lessen the possibility
of a voltage drop cause by a loose “B” terminal connection.
5. Connect a digital-type voltmeter between the alternator “B” terminal and the battery (+) terminal
(connect the (+) lead of the voltmeter to the battery (+) cable.)
6. Reconnect the battery (-) cable.
7. Connect a tachometer or the PADT-II.
8. Leave the hood open.
9. Start the engine
10. With the engine running at 2500 r/min, turn the headlamp and other lamps on and off to adjust
the alternator load so that the value displayed on the ammeter is slightly above 30 A.
Adjust the engine speed by gradually decreasing it until the value displayed on the ammeter is
30 A. Take a reading of the value displayed on the voltmeter at this time.
Limit :
Maximum 0.3 V
NOTE
When the alternator output is high and the value displayed on the ammeter does not decrease
until 30 A, set the value to 40 A. Read the value displayed on the voltmeter at this time
11.
T
When the value range is 40 A, the limit is maximum 0.4 V.
If the value displayed on the voltmeter is above the limit value, there is probable a malfunction
in the alternator output wire, so check the wiring between the alternator “B” terminal and the
AF
battery (+) terminal (including fusible link).
If a terminal is not sufficiently tight or if the harness has become discolored due to overheating,
repair and then test again.
12. After the test, run the engine at idle.
13. Turn off all lamps and the ignition switch.
14. Remove the tachometer or the PADT-II.
15. Disconnect the battery (-) cable
R
16. Disconnect the ammeter and voltmeter.

17. Connect the alternator output wire to the alternator “B” terminal.
18. Connect the battery (-) cable.
D

CHARGING SYSTEM /9
OUTPUT CURRENT TEST
T
AF
R
DOINC016R11004
Symbol Description
A Charging warning lamp (integrated in meter cluster)
D
B Terminal B
C Ignition switch
D Battery
E Voltmeter
F Ammeter
H Alternator
I Load
J Engine control unit (ECU)
This test determines whether the alternator output current is normal.
1. Before the test, always be sure to check the following.
• Battery (Refer to GROUP 054 – Chassis Electrical).
NOTE
The battery should be slightly discharged.
The load needed by a fully-charged battery is insufficient for an accurate test.
• Fusible link.

/ 10 CHARGING SYSTEM

3. Disconnect the battery (-) cable.
4. Disconnect the alternator output wire from the alternator “B” terminal. Connect a DC test ammeter
with a range of 0-100 A in series between the “B” terminal and the disconnected output wire
(connect the (+) lead of the ammeter to the “B” terminal, connect the (-) lead of the ammeter to
the disconnected output wire.)
CAUTION
Never use clips. Tighten bolts and nuts to connect the line, otherwise loose connections (e.g. using
clips) will lead to a serious accident because of high current.
NOTE
An inductive-type ammeter which enables measurements to be taken without disconnecting the
alternator output wire should be recommended.
5. Connect a voltmeter with a range of 0-20 V between the alternator “B” terminal and the earth
(connect the (+) lead of the voltmeter to the “B” terminal, and then connect the (-) lead of the
voltmeter to the earth.)
8. Leave the hood open.
T
9. Check that the reading on the voltmeter is equal to the battery voltage.
NOTE
If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the
AF
alternator “B” terminal and the battery (+) terminal.
10. Turn on the ignition switch and then the head lamps and then start the engine.
11. Immediately after setting the headlamp to high beam, increase the engine speed to 2500 r/min
and read the maximum current output value displayed on the ammeter.
Limit:
70% of normal current output
R
NOTE
• For the nominal current output, refer to alternator specifications.
• Because the current from the battery soon drop after the engine is started, the above step
D
should be carried out as quickly as possible in order to obtain the maximum current output
value.
• The current output value will depend on the electrical load and the temperature of the altern-
ator body.
• If the electrical load is small while testing, the specified level of current may not be out even
though the alternator is normal. In such cases, increase the electrical load by leaving the
headlamp turned on some time to discharge the battery or by using the lighting system in
another vehicle, and then test again.
• The specified level of current also may not be out if the temperature of the alternator body
or the ambient temperature is too high. In such cases, cool the alternator and then test again.
12. The reading on the ammeter should be above the limit value. If the reading is below the limit
value and the alternator output wire is normal, remove the alternator from the engine and check
the alternator.
13. Run the engine at idle after the test.
14. Turn the ignition switch off.
17. Disconnect the ammeter and voltemeter.
18. Connect the alternator output wire to the alternator “B” terminal.

CHARGING SYSTEM / 11
REGULATED VOLTAGE TEST
T
AF
R
DOINC016R11005
Symbol Description
A Charging warning lamp (Integrated in meter cluster)
D
B Ignition switch
C Battery
D Voltmeter
E Ammeter
F Alternator
G Yellow (testing wire)
H Load
I Engine control unit (ECU)
This test determines whether the voltage regulator is correctly controlling the alternator output
voltage.
1. Always be sure to check the following before the test.
• Check that the battery installed in the vehicle is fully charged. (Refer to GROUP 054 — Chassis
Electrical).
• Fusible link.


4. Use the special tool (alternator test harness) to connect a digital voltmeter between the alternator
“S” terminal and earth (connect the (+) lead of the voltmeter to the “S” terminal, and then connect
the (-) lead of the voltmeter to the earth or to the battery (-) terminal.)
5. Disconnect the alternator output wire from the alternator “B” terminal.
6. Connect a DC test ammeter with a range of 0-100 A in series between the “B” terminal and the
disconnected output wire (connect the (+) lead of the ammeter to the “B” terminal, connect the
(-) lead of the ammeter to the disconnected output wire.)
7. Reconnect the negative battery cable.
9. Turn on the ignition switch and check that the reading on the voltmeter is equal to the battery
voltage.
NOTE
If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the
alternator “S” terminal and the battery (+) terminal.
10. Turn all lamps and accessories off.
11. Start the engine.
12. Increase the engine speed to 2500 r/min.
13. Read the value displayed on the voltmeter when the alternator output current alternator become
10 A or less.
14.
T
If the voltage reading confirm to the value in the voltage regulation, then the voltage regulator
is operating normally.
If the voltage is not within the standard value, there is a malfunction of the voltage regulator or
AF
the alternator.
15. After the test, lower the engine speed to the idle speed.
19. Disconnect the ammeter and voltmeter.
R
20. Connect the alternator output wire to alternator “B” terminal.

21. Remove the special tool and return connector to the original condition.
VOLTAGE REGULATION STANDARD TABLE
D
Inspection terminal Voltage regulator ambient temperature Voltage

-20 °C (-4 °F) 14.2-
15.4
V
20 °C (68 °F) 13.9-
14.6
V
Terminal “S”
60 °C (140 °F) 13.4-
14.6
V
80 °C (176 °F) 13.1-
14.5
V

WAVEFORM CHECK USING AN ANALYZER

Symbol Description
A Alternator
B Terminal B
C Special patterns pick-up
D Analyzer
MEASUREMENT METHOD
Connect the analyzer special patterns pick-up to
the alternator “B” terminal.
DOINC016R11006
NOTE
The voltage waveform of the alternator “B”
terminal can undulate as shown in the illustra-
tion. This waveform is produced when the regu-
lator operates according to fluctuations in the
alternator load (current), and is normal for the
alternator.
T
AF
DOINC016R11007
STANDARD WAVEFORM (OBSERVATION CONDITIONS)

Function Special patterns
R
Pattern height Variable

Variable knob Adjust while viewing the waveform
Pattern selector Raster
D
Engine speed Curb idle speed

T
AF
DOINC016R11008
R
Symbol Description
A Time
B Voltage at alternator “B” terminal
D
EXAMPLES OF ABNORMAL WAVEFORMS

NOTE
(1) The size of the waveform patterns differs largely, depending on the adjustment of the variable
knob on the analyzer.
(2) Identification of abnormal waveforms is easier when there is a large output current (regulator is
not operating). (Waveforms can be observed when the headlamp are illuminated).
(3) Check the condition of the charging warning lamp (illuminated/not illuminated). Also, check the
charging system totally.

Abnormal waveforms Problem cause

Examples 1 • Open diode
DOINC016R11009
Examples 2 • Short in diode
T
AF
R
DOINC016R11010
Examples 3 • Broken wire in

stator coil
D
DOINC016R11011

Abnormal waveforms Problem cause

Examples 4 • Short in stator coil
DOINC016R11012
Examples 5 • Open supplement-

ary diode.
At this time, the
charging warning
T lamp is illuminated.
AF
R
DOINC016R11013
D

ALTERNATOR WCH016SASSY11001
REMOVAL AND INSTALLATION <CFE>
T
AF
R
DOIQC016R11002
Pre-removal and Post-installation Operation:

D
• Fead Belt Removal and Installation (Refer to 16/29 )

• Splash Shield (RH) Removal and Installation (Refer to GROUP 042 – Body)
Removal steps
1. Fead belt tensioner
2. Fead belt
3. Alternator
T1 : 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
T2 : 3.3-3.7 kgm (33-37 Nm, 23.87-26.76 ft.lbs)
T3 : 4.8-5.2 kgm (48-52 Nm, 34.72-37.61 ft.lbs)
T4 : 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)

REMOVAL AND INSTALLATION <IAFM+>
T
AF
R
DOIQC016R11001
Pre-removal and Post-installation Operation:

• Fead Belt Removal and Installation (Refer to 16/29 )
D
• Splash Shield (RH) Removal and Installation (Refer to GROUP 042 – Body)
Removal steps
2. Fead belt
3. Alternator
T1 : 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
T2 : 3.3-3.7 kgm (33-37 Nm, 23.87-26.76 ft.lbs)
T3 : 4.8-5.2 kgm (48-52 Nm, 34.72-37.61 ft.lbs)
T4 : 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)

DISASSEMBLY AND REASSEMBLY <CFE & IAFM+> WCH016SASSY11002
T
AF
R
DOINC016R09003
Disassembly steps
1. Protective cap 11. Startor
D
2. Overrunning alternator pulley 12. Screw washer

3. Bolt 13. Regulator assembly
4. Flange screw 14. Rectifier assembly
5. Rotor assembly 15. Rear bracket
6. Rear bearing 16. Bush
7. Spacer 17. Cover
8. Bearing retainer 18. Nut
9. Front bearing 19. Terminal B
10. Front bracket
T1 : 3.0-5.0 Kgf.m
T2 : 2.0-5.5 Kgf.m
T3 : 7.0–8.6 Kgf.m
T4 : 6.0-10.0 Kgf.m

REMOVAL SERVICE POINT <CFE>

WCH016SPROC11002
CAUTION
(1) Disconnect the negative (-) battery cable and
tape the terminal.
(2) Wait at least 5 minutes after disconnect the
Symbol Description
A Insulating cover
B Negative (—) battery cable
DOIQC52BR12030
C Battery
1. Release fead belt.
2. Remove alternator harness nut (alternator
(+) connector).
T
AF
DOIQC016R12002
3. Remove alternator connector.

R
D
DOIQC016R12003

4. Remove alternator lower nut.
DOIQC016R12005
5. Remove alternator upper nut.
T
AF
DOIQC016R12007
6. Remove alternator.
R
D
DOIQC016R12009
REMOVAL SERVICE POINT <IAFM+>

CAUTION
(1) Disconnect the negative (-) battery cable and
tape the terminal.
(2) Wait at least 5 minutes after disconnect the
Symbol Description
A Insulating cover
B Negative (—) battery cable
C Battery
DOIQC52BR12030

1. Release fead belt.

2. Remove alternator upper bolt.
Symbol Description
A Bolt
B Timing belt upper cover
C Water pump pulley
DOIIC016R07002
3. Lift-up the car using car lifter.

4. Remove intake manifold bracket based on
steps below.
Step Item
1 Remove 2 pieces bolts (G)
2 Remove 2 pieces torx bolts (H)
T Symbol
D
Description
Intake manifold
AF
E Intake manifold bracket
F Drive shaft
DOIIC016R07003
G Bolt
H Torx bolt
5. Release alternator “B” terminal slowly and
R
carefully from alternator.
Symbol Description
J “B” terminal
D
DOIIC016R07008

6. Remove alternator lower nut and bolt.
Symbol Description
K Nut
L Bolt
M Oil cooler
DOIIC016R07016
7. Slowly move the alternator downward based

on 'APM' marking angle in 90° as shown in
the llustration.
Symbol Description
E Intake manifold
F Drive shaft
T M
N
Oil cooler
'APM' marking
AF
DOIIC016R07005
8. Remove the alternator until it pass by drive-

shaft as shown in the illustration. The 'APM'
marking angle must always in 90°∼ 95° to
R
ensure it is removed easily .
Symbol Description
E Intake manifold
D
F Drive shaft
DOIIC016R07006
9. Completely remove the alternator based on

angle shown in the illustration.
Symbol Description
E Intake manifold
F Drive shaft
P Steering linkage
10. Lift-down the car lifter.
DOIIC016R07007

ALTERNATOR DISASSEMBLY SERVICE

POINTS <CFE & IAFM+> WCH016SPROC11003
ALTERNATOR PULLEY REMOVAL

1. Remove the bolts
2. Insert a flat-tipped screwdriver between
front bracket stator core and pry downwards.
CAUTION
Do not insert a screwdriver too deep, as the
stator coil will be damaged.
DOINC016R11015
3. Clamp the rotor in a vice with soft jaws.

4. After removing the protective cap, remove
the alternator pulley by using special tool
EZT 0040 and front bracket from the rotor.
Symbol Description
A Special tool EZT 0040
T
AF
DOINC016R11027
STATOR REMOVAL
1. When removing stator, unsolder three stator
R
leads to main diodes on rectifier.
Symbol Description
A Soldered point
D
2. When removing rectifier from brush holder,

unsolder two soldered points to rectifier.
CAUTION
(1) When soldering or unsoldering, use care
DOINC016R11016
to make sure that heat of soldering iron
is not transmitted to diodes for a long
period. Finish soldering or unsoldering
in as short time as possible.
(2) Use care that no undue force is exerted
to leads of diodes.

REASSEMBLY SERVICE POINT <CFE &

IAFM+>
ROTOR ASSEMBLY INSTALLATION
1. Before rotor is attached to rear bracket, in-
sert wire through small hole made in rear
bracket to lift brush. After rotor has been
installed, remove the wire.
Symbol Description
A Rear bracket
DOINC016R11017 B Brush
C Wire
T
AF
DOINC016R11018
INSPECTION <CFE & IAFM+>

R
ROTOR
1. Check rotor coil for continuity. Check that
there is no continuity between slip rings. If
resistance is too small, it means that there is
D
a short circuit. If there is continuity or if there

is a short circuit, replace rotor assembly.
Resistance value:
Approximate3 Ω
DOINC016R11019

2. Check rotor coil for earthing. Check that

there is continuity between slip ring and
core. If there is continuity replace rotor as-
sembly.
DOINC016R11020
STATOR
1. Make continuity test on stator coil. Check
that there is continuity between coil leads.
If there is no continuity replace stator as-
sembly.
2. Check coil for earthing. Check that there is
T
no continuity between coil and core. If there
is continuity, replace stator assembly.
AF
DOINC016R11021
RECTIFIERS
1. Positive Rectifier Test
R
Check for continuity between positive recti-

fier and stator coil lead connection terminal
with an ohmmeter. If there is continuity in
both directions, diode is shorted; replace
D
rectifier assembly.
DOINC016R11022
2. Negative Rectifier Test

Check for continuity between negative recti-
fier and stator coil lead connection terminal.
If there is continuity in both directions, diode
is shorted; replace rectifier assembly.
DOINC016R11023

3. Diode Trio Test

Check three diodes for continuity by connect-
ing an ammeter to both ends of each diode.
If there is no continuity in both directions,
diode is faulty and heatsink assembly must
be replaced.
DOINC016R11024
BRUSH REPLACEMENT
1. Replace brush by using the following proced-
ures if it has been worn to limit line.
Symbol Description
A Limit line
T
AF
DOINC016R09006
2. Unsolder pigtail and remove old brush and

spring.
R
Symbol Description
A Soldered
D
DOINC016R11025
3. When installing a new brush, push the brush

in the brush holder as shown in the illustra-
tion and solder the lead wire.
DOINC016R11026

ALTERNATOR WCH016SPROC11004
FEAD BELT ROUTE <CFE & IAFM+>
T
AF
R
DOINC016R11070
Symbol Description
D
1 Tensioner assy drive pulley

2 TV damper pulley
3 Compressor pulley
5 Upper water pump pulley
6 Alternator pulley
7 Lower water pump pulley
TI 4.8-5.2 kgm (48-52 Nm, 34.72-37.61 ft.lbs)
T2 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)

FEAD BELT DRIVE REMOVAL SERVICE

FEAD BELT REMOVAL

arm.
Symbol Description
A Ratchet
DOIGC11AR03025

or.
T Symbol
A Ratchet
Description
AF
DOIGC11AR03026
FEAD BELT DRIVE INSTALLATION SERVICE

POINTS <CFE & IAFM+>
R

D

torque.
Symbol Description
DOIGC11AR03027
4.8-5.2 kgm (48-52 Nm, 34.72-
T1
37.61 ft.lbs)
2.2-2.6 kgm (22-26 Nm, 15.91-
T2
18.81 ft.lbs)


roller nicely.
NOTE
Symbol Description
1 Fead belt
DOIGC11AR03028

arm.
Symbol Description
A Ratchet
T
AF
DOIGC11AR03029

R
Symbol Description
A Ratchet
1 TV damper
D
2 Compressor pulley
4 Water pump pulley
DOIGC11AR03030

Symbol Description
A Ratchet
5 Alternator pulley
6 Water pump pulley
DOIGC11AR03031

STARTING SYSTEM / 31
STARTING SYSTEM WCH016GINFO11002
GENERAL INFORMATION
If the ignition switch is turned to the “START” position, current flows in the coil provide inside mag-
netic switch, attracting the plunger. When the plunger is attracted, the lever connected to the plunger
is actuated to engage the starter clutch.
On the other hand, attracting the plunger will turn on the magnetic switch, allowing the B terminal
and M terminal to conduct. Thus, current flows to engage the starter motor.
When the ignition switch is returned to the “ON” position after starting the engine, the starter clutch
is disengaged from the ring gear.
An overrunning clutch is provided between the pinion and the armature shaft to prevent damage to
the starter.
T
AF
R
D

/ 32 STARTING SYSTEM
SYSTEM DIAGRAM
T
AF
R
DOINC016R11034
Symbol Description
A Battery
D
B Ignition switch
C Inhibitor switch <A/T>
D Pull-in coil
E Holding coil
F Armature
G Brush
H Yoke
I Field coil (Direct drive type only)
SPECIFICATIONS <CFE & IAFM+> WCH016SPECS11002
M/T — CVT
Items
1.6
Design specification 12 V - 0.9 kW
Rotation Clockwise (viewed on drive end)
Type Direct drive
No. of pinion teeth 8

Starter motor mounting bolt 2.8-3.2 kgm (28-32 Nm, 20.25-23.15 ft.lbs)
T
AF
R
D

STARTER MOTOR WCH016SASSY11003
REMOVAL AND INSTALLATION <CFE & IAFM+>
T
AF
R
DOINC016R11071
CAUTION
D
Disconnect battery terminal before remove the starter motor.

Removal steps
1. Negative (-) battery cable
2. Battery
3. Insulating tape
4. Starter bolt
5. Starter motor connector harness
6. Starter motor
T1 : 2.8-3.2 kgm (28-32 Nm, 20.25-23.15 ft.lbs)

REMOVAL SERVICE POINT <CFE>

WCH016SPROC11006
1. Disconnect starter motor connector and

starter motor cable plate from starter motor.
Symbol Description
A Starter motor connector
B Starter motor cable plate
DOIQC016R12013
2. Remove stater motor nut harness (starter

motor (+) connector).
T
AF
DOIQC016R12011
3. Remove starter motor bolt (2 pieces).

R
D
DOIQC016R12012
4. Remove starter motor from transmission case

slowly and carefully.
Symbol Description
C Starter motor
DOIQC016R12014

REMOVAL SERVICE POINT <IAFM+>

1. Remove first starter motor bolt which located
under thermostat pipe area.
Symbol Description
A First starter motor bolt
B Thermostat pipe
DOIIC016R07009
2. Remove the second starter motor bolt.
Symbol Description
C Second starter motor bolt
T
AF
DOIIC016R07010
3. Disconnect starter motor connector and

starter motor cable plate from starter motor.
R
Symbol Description
D Starter motor connector
E Starter motor cable plate
D
DOIIC016R07011
4. Remove starter motor from transmission case

slowly and carefully.
Symbol Description
F Starter motor
DOIIC016R07012

STARTER MOTOR REMOVAL <CFE &

IAFM+> WCH016SPROC11007
TERMINAL MAGNETIC SWITCH INSPECTION

Symbol Description
A Terminal S
B Magnetic switch
C Terminal B
D Terminal M
E File coil wire
DOIGC016R08001
1. Disconnect battery terminal before removing

the starter motor
2. Disconnect stater harness, and then push the
starter motor to the top of intake manifold
as shown in illustration.
Symbol Description
T 1
2
Battery cable (—)
Insulating cover
AF
3 Battery
4 Stater motor bolts
5 Starter motor connector harness
6 Starter motor push up direction
R
D
DOINC016R11072
PINION GAP ADJUSTMENT

1. Disconnect the field coil wire from terminal
M of the magnetic switch.
2. Connect a 12 V battery between terminal S
and terminal M.
Symbol Description
A Switch
B Terminal B
C Battery
D Starter motor
DOINC016R11035 E Field coil wire

Symbol Description
M Terminal M
S Terminal S
3. Set switch to “ON”, and pinion will move
out.
CAUTION
This test must be performed quickly (in less
than 10 seconds) to prevent coil from burn-
ing.
4. Check pinion to stopper clearance (pinion
gap) with a thickness gauge.
Pinion gap:
0.5 - 2.0 mm (0.02 - 0.079 in)
Symbol Description
A Stopper
B Pinion gap
T
C Pinion
AF
DOINC016R11036
5. If pinion gap is out of specification, adjust

by adding or removing gasket between
magnetic switch and front bracket.
Symbol Description
A Fiber washer
R
D
DOINC016R11037
MAGNETIC SWITCH PULL-IN TEST

1. Disconnect field coil wire from terminal M
of magnetic switch.
and terminal M.
Symbol Description
A Battery
B Field coil wire disconnect connect-
or
C Starter motor
DOINC016R11038 CAUTION
ing.

3. If pinion moves out, then pull-in coil is good.

If it does not moves out, replace magnetic
switch.
MAGNETIC SWITCH HOLD-IN TEST
of magnet switch.
and the body.
Symbol Description
A Battery
B Field coil wire disconnect connect-
or
C Starter motor
DOINC016R11039 CAUTION
ing.
T
3. Manually pull out the pinion as far as the
pinion stopped position.
4. If pinion remains out, everything is in order.
AF
If pinion moves in, hold-in circuit is open.
Replace magnetic switch.
FREE RUNNING TEST
1. Place starter motor in a vise equipped with
soft jaws and connect a fully-charged 12 V
battery to starter motor as follows:
R
Symbol Description
C Carbon-pile rheostat
D Ammeter
D
E Battery
F Voltmeter
G Starter motor
DOINC016R11040
2. Connect a test ammeter (100 A scale) and
carbon pile rheostat in series with battery
positive post and starter motor terminal.
3. Connect a voltmeter (15 V scale) across
starter motor.
4. Rotate carbon pile to full-resistance position.
5. Connect battery cable from battery negative
post to starter motor body.
6. Adjust the rheostat until the battery voltage
shown is 11.5 V.
7. Confirm that the maximum amperage is
within the specifications and that the starter
motor turns smoothly and freely.
Current :
60 A (maximum)

MAGNETIC SWITCH RETURN TEST

of magnetic switch.
2. Connect a 12 V battery between terminal M
and body.
Symbol Description
A Battery
B Field coil wire
C Starter motor
CAUTION
DOINC016R11041 This test must be performed quickly (in less
ing.
3. Pull pinion out and release it back. If pinion
quickly returns to its original position,
everything is in order. If it does not returns
to original position, replace magnetic switch.
T
CAUTION
Be careful not to get your fingers caught
when pulling out the pinion.
AF
R
D

STARTER MOTOR <CFE & IAFM+> WCH016SASSY11004
T
AF
R
DOIGE16BR08002
Disassembly steps
D
1. Bracket front 14. Yoke assy

2. Sleeve bearing (F) 15. Armature assy
3. Shaft assy gear 16. Connector brush holder
4. Internal gear assy 17. Cover (Rear)
5. Overruning clutch 18. Sleeve bearing rear
6. Stopper 19. Cover
7. 20. Hexagon head bolt
Ring
8. 21. Switch assy
Lever
9. 22. Support
Flange screw
10. 23. Terminal B
Plate (lever)
11. 24. Cap (terminal B)
Packing
12. 25. Hexagon nut
Gear assy
13. 26. Flange screw
Internal gear assy
T1 : 4.2-7.7 kgfm
T2 : 3.9-7.2 kgfm
T3 : 2.4-4.5 kgfm
T4 : 9.0-13.0 kgfm

STARTER MOTOR DISASSEMBLY SERVICE

MAGNETIC SWITCH REMOVAL

Disconnect the field coil wire from terminal M
of the magnetic switch.
Symbol Description
A Terminal S
B Magnetic switch
C Terminal B
DOIGC016R08001 D Terminal M
E File coil wire
SNAP RING/STOP RING REMOVAL

1. Press stop ring off snap ring with a suitable
socket.
Symbol Description
T A
B
Stop ring
Armature
AF
C Socket
D Pinion gear
E Overrunning clutch
DOINC016R11042
2. Remove snap ring by using snap ring pliers

R
and then remove stop ring and overrunning

clutch.
Symbol Description
D
A Snap ring
B Pinion gear
C Overrunning clutch
D Snap ring plier
STARTER MOTOR PARTS CLEANING <CFE

DOINC016R11043
& IAFM+>
1. Do not immerse parts in cleaning solvent.
Immersing the yoke and field coil assembly
and/or armature will damage insulation.
Wipe these parts with a cloth only.
2. Do not immerse drive unit in cleaning
solvent. Overrunning clutch is pre-lubricated
at the factory and solvent will wash lubrica-
tion from clutch.
3. The drive unit may be cleaned with a brush
moistened with cleaning solvent and wiped
dry with a cloth.

STARTER MOTOR REASSEMBLY SERVICE

POINTS <CFE & IAFM+>
STOP RING/SNAP RING INSTALLATION
Using a suitable pulling tool, pull overrunning
clutch stop ring over snap ring.
Symbol Description
A Stop ring
B Overrunning clutch
C Stop ring
DOINC016R11044
D Snap ring
STARTER MOTOR INSTALLATION

NOTE:
Before installing the starter motor, ensure the
magnetic switch coil wire at the correct position
(at terminal M as shown in illustration).
T Symbol
A
Description
Terminal S
AF
B Magnetic switch
C Terminal B
DOIGC016R08001
D Terminal M
E File coil wire
INSPECTION <CFE & IAFM+>
R
COMMUTATOR
1. Place the armature in a pair of “V” block and
check the runout with a dial indicator.
D
Limit :
0.05 mm (0.002 in)
DOINC016R11045

2. Measure the commutator outer diameter.

Standard value:
32.0 mm (1.26 in)
Limit: 31.4 mm (1.24 in)
DOINC016R11046
3. Check the undercut depth between seg-

ments.
Symbol Description
A Segment
B Undercut
T
C Mica
Standard value:
0.5 mm (0.02 in)
AF
Limit: 0.2 mm (0.008 in)
DOINC016R11047
FIELD COIL OPEN-CIRCUIT TEST

Check the continuity between field brushes. If
there is continuity, the field coil is in order.
R
D
DOINC016R11048
FIELD COIL GROUND TEST

Check the continuity between field coil brush
and yoke, if there is no continuity, the field coil
is free from the earth.
Symbol Description
A Field brush
B Yoke
DOINC016R11049

BRUSH HOLDER
Check the continuity between brush holder plate
and brush holder. If there is no continuity, the
brush holder is in order.
Symbol Description
A Insulated brush holder
DOINC016R11050
OVERRUNNING CLUTCH
1. While holding clutch housing, rotate the
pinion. Drive pinion should rotate smoothly
in one direction, but should not rotate in
opposite direction. If clutch does not function
properly, replace overrunning clutch as-
T
sembly.
Symbol Description
A Free
AF
B Lock
DOINC016R11051
2. Inspect pinion for wear or burrs. If pinion is
worn or burred, replace overrunning clutch
assembly. If pinion is damaged, also inspect
ring gear for wear or burrs.
R
FRONT AND REAR BRACKET BUSHING

Inspect bushing for wear or burrs. If bushing is
worn or burred, replace front bracket assembly
D
or rear bracket assembly.

BRUSH AND SPRING REPLACEMENT <CFE
& IAFM+>
1. Brushes that are worn beyond wear limit line,
or are oil-soaked, should be replaced.
Symbol Description
A Wear limit line
2. When replacing field coil brushes, crush worn
brush with pliers, taking care not to damage
pigtail.
DOINC016R11052

Symbol Description
A Pigtail
B New brush
C Soldered (make sure that there is no
excess solder on brush surface)
D Surface marked
3. Sand pigtail end with sandpaper to ensure
good soldering.
4. Insert pigtail into hole provided in new brush
and solder it.
DOINC016R11053 NOTE
Make sure that pigtail and excess solder do
not come out onto brush surface.
5. When replacing ground brush, slide the
brush from brush holder by prying retainer
spring back.
ARMATURE TEST <CFE & IAFM+>
T
ARMATURE SHORT-CIRCUIT TEST
1. Place armature in a growler.
AF
Symbol Description
A Growler
2. Hold a thin steel blade parallel and just
above while rotating armature slowly in
growler. A shorted armature will cause blade
to vibrate and be attracted to the core. Re-
R
place shorted armature.

DOINC016R11054
ARMATURE COIL EARTH TEST

D
Check the insulation between each commutator

segment and armature coil core.
If there is no continuity, the insulation is in order.
DOINC016R11055

IGNITION SYSTEM / 47
ARMATURE COIL OPEN-CIRCUIT INSPECTION

Check the continuity between segments. If there
is continuity the coil is in order.
DOINC016R11056
IGNITION SYSTEM WCH016GINFO11003
GENERAL INFORMATION
IGNITION COIL
The system is provided with four top coils with built-in ignition power transistor for each of the cylin-
ders.
T
Interruption of the primary current flowing in the primary side of top coil generates a high voltage
in the secondary side of top coil.
AF
The engine control unit (ECU) controls the two ignition power transistors to turn them alternately
ON and OFF. This causes the primary to be alternately interrupted and allowed to flow to fire the
cylinders in the order 1–3–4–2.
The engine - ECU determines which top coil should be controlled by means of the signals from the
camshaft position sensor which is incorporated in the crankshaft. It also detects the crankshaft position
in order to provide ignition at the most appropriate timing in response to the engine operation con-
ditions.
R
When the engine is cold or operated at high altitudes, the ignition timing is slightly advanced to
provide optimum performance. Furthermore, if knocking occurs, the ignition timing is gradually re-
tarded until knocking ceases.
D

/ 48 IGNITION SYSTEM
SYSTEM DIAGRAM
T
AF
R
DOINC016R11057
Symbol Description
A Engine control relay
D
B Battery
C Cylinder no. (spark plugs)
D Top coil no.
E To tachometer
F Power transistors (integrated in ECU)
IGNITION COIL <CFE & IAFM+>

Items Specification
Type Electronic
HT Ignition peak voltage 32 kV
Spark energy > 60mJ.
Primary: 3.7mH ± 0.37mH
Induction
Secondary: 38.0H ± 3.8H
Resistance 0.5 Ω ± 0.05 Ω
Degree of protection IP X 4A According to DIN400 50 B1.9

Items Specification
S operation: -40 °C (-40 °F) to 140 °C (284 °F)
Temperature
Rubber seal: 140 °C (284 °F) MAX
Normal voltage 6-16 V
SPARK PLUG <CFE>
Items Specification
NGK ILKAR7G7 — Iridium Platinum Type
Spark plug gap 0.6-0.7 mm (0.024-0.028 in)
SPARK PLUG <IAFM+>
Items Specification
NGK BPR6EF-11
Spark plug gap 1.0-1.1 mm (0.039-0.043 in)
Top coil bolt 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
Spark plug <CFE>
Spark plug <IAFM+>
T
1.75 kgm (17.5 Nm, 12.66 ft.lbs) ± 0.25 kgm (2.5 Nm, 1.81 ft.lbs)
1.5 kgm (15 Nm, 10.85 ft.lbs) ± 0.5 kgm (5 Nm, 3.62 ft.lbs)
AF
Cam position sensor bolt 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
Crank sensor screw 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Engine cover bolt 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
R
D

REMOVAL AND INSTALLATION <CFE> WCH016SASSY11005
T
AF
R
DOIQC016R12016
Removal steps
1. Nut
D
2. Engine cover
3. Top coil
4. Spark plug
5. Cam sensor
6. Crank sensor
T1 : 0.5-0.7 kgm (5-7 Nm, 3.62-5.06 ft.lbs)
T4 : 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)

REMOVAL AND INSTALLATION <IAFM+>
T
AF
R
DOIQC016R12015
Removal steps
1. Nut
D
2. Engine cover
3. Top coil
4. Spark plug
5. Cam sensor
6. Crank sensor
T1 : 0.5-0.7 kgm (5-7 Nm, 3.62-5.06 ft.lbs)
T4 : 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)

SPARK PLUG CHECK AND CLEANING

1. Remove the top plug coil.
CAUTION
When pulling off the top plug coil, always
handle the top plug with care.
2. Remove the spark plugs.
3. Check the burned out electrode or damaged
insulator.
4. Remove carbon deposits with wire brush or
plug cleaner.
5. Remove sand from plug screw with com-
pressed air.
6. Use a plug gap gauge to check that the plug
gap is within the standard value range.
Symbol Description
A Plug gap
T
Spark plug gap:
<CFE>0.6-0.7 mm (0.024-0.028 in)
<IAFM+>1.0-1.2 mm (0.039-0.047 in)
AF
If the plug gap is not within the standard
value range, adjust by bending the ground
electrode.
DOINC016R11060 7. Clean the engine plug holes.
CAUTION
Use care not to allow foreign matters in cyl-
R
inders.
8. Install spark plug to cylinder head assy with
the specified torque value.
D
Specified torque:
<CFE> 1.75 kgm (17.5 Nm, 12.66 ft.lbs) ±0.25
kgm (2.5 Nm, 1.81 ft.lbs)
<IAFM+> 1.5 kgm (15 Nm, 10.85 ft.lbs) ±0.5

INSPECTION WCH016SPROC11013
IGNITION COIL CHECK <CFE & IAFM+>

This procedure can be used to check all top coil
1,2,3 and 4.
Symbol Description
A Top coil
B Top coil connector
C1 Top coil 1 location
Measure the resistance of the ignition coil using
multimeter:
Terminal Resistance
Between terminal 1 and
0.5 Ω ± 0.05 Ω
terminal 2
T If the measurement value is out of specification,

replace the top coil (refer to Group 054 Chassis
Electrical- Ignition system for details).
AF
DOINC016R11058
WAVEFORM CHECK USING V.M.I OSCILLOSCOPE WCH016SASSY11006

R
MEASUREMENT METHOD
1. Insert the probe to the top coil wire harness as shown in the illustration.
2. Check the waveform measurement reading from the PADT-07 software in computer.
D
DOINC016R11061
STANDARD WAVEFORM OBSERVATION CONDITIONS

Function Secondary
Pattern height High or low
Pattern selector Raster
Engine Speed Curb idle speed

T
AF
DOINC016R11062
R
Symbol Description
I Ignition secondary voltage waveform
II Ignition voltage (Point D)
D
III Spark line (Point A)

IV Vibration damping section (Point B)
V Dwell section
VI Point C
VII Time
WAVEFORM OBSERVATION POINTS
POINT A : The height , length and slope of the spark line show the following trends (Refer to abnormal
waveform examples , 1 , 2 , 3, 4 and 5 )
Spark line Plug gap Condition of Compression Concentra- Ignition Spark

electrode force tion of air timing plug
mixture cable
Long Small Normal Low Rich Advanced Leak
Length Short Large Large wear High Lean Retarded High
resist-
ance

Spark line Plug gap Condition of Compression Concentra- Ignition Spark

electrode force tion of air timing plug
mixture cable
High Large Large wear High Lean Retarded High
resist-
Height ance
Low Small Normal Low Rich Advanced Leak
Slope Large Plug is — — — — —
fouled
POINT B : Number of vibration in reduction vibration section (Refer to abnormal waveform example
5)
Number of vibrations Coil and condenser

Three or more Normal
Except above Abnormal
POINT C : Number of vibrations at beginning of dwell section (Refer to abnormal waveform examples
5)
Number of vibrations Coil

5–6 or higher
Except above
T
Normal
Abnormal
AF
POINT D : Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition Plug gap Condition of Compression Concentra- Ignition tim- Spark plug
voltage electrode force tion of air ing cable
mixture
High Large Large wear High Lean Retarded High resistance
Low Small Normal Low Rich Advanced Leak
R
EXAMPLES OF ABNORMAL WAVEFORMS

Abnormal waveform Wave characteristics Cause of problem
D
Examples 1 Spark line is high and short Spark plug gap is too
large
DOINC016R11063
Examples 2 Spark line is low and long , Spark plug gap is too
and is sloping. small
Also , the second half of the
spark line is distorted. This
could be a result of misfir-
ing.
DOINC016R11064

Abnormal waveform Wave characteristics Cause of problem

Examples 3 Spark line is low and long , Spark plug gap is
and is sloping . However , fouled
there is almost no spark line
distortion.
DOINC016R11065
Examples 4 Spark line is high and short. Spark plug cable is

Difficult to distinguish nearly falling off.
between this and abnormal (Causing a dual igni-
waveform examples 1. tion)
DOINC016R11066
Examples 5 No waves in wave damping Layer short in ignition

section coil
T
AF
DOINC016R11067
R
D

EXAMPLE OF NORMAL WAVEFORM WCH016SASSY11008
T
AF
R
DOINC016R11073
Voltage/Division = 50V Measurement type = Time /Division = 20 Horizontal level = -3

Normal ms
D

T
AF
DOINC016R11074
R
Voltage/Division = 5V Measurement type = Time /Division = 20 Horizontal level = -2

Normal ms
D

T
AF
DOINC016R11075
R
Maximum Current Drawn by Injector = V =IR

I =V/R I + 185.0 / 0.3 I = 6.6.67 Amp
D

/ 60 DETONATION/KNOCK SENSOR
DETONATION/KNOCK SENSOR WCH016SASSY11007
T
AF
R
DOINC016R11068
D
Removal steps
1. Detonation/knock sensor
INSPECTION
DETONATION/KNOCK SENSOR CHECK
Refer to Group 13A

DETONATION / KNOCK SENSOR / 61
DETONATION / KNOCK SENSOR

WCH016SPROC11011

KNOCK SENSOR INSTALLATION
1. Install the knock sensor to cylinder block and
tighten the bolt flange.
Specified torque (T1):
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.5 kgm (5
Nm, 3.62 ft.lbs)
DOINC016R11069 NOTE
Knock sensor terminal facing outward.
Symbol Description
A Knock sensor
T
AF
R
D

/ 62 DETONATION / KNOCK SENSOR
NOTE
T
AF
R
D

EMISSION CONTROL<CFE> 17
Content /1
17 EMISSION CONTROL<CFE>
GENERAL SPECIFICATIONS .......................................................... 17/4
SPECIFICATIONS ..................................................................... 17/4
SPECIAL TOOLS ........................................................................ 17/4
SPECIFICATIONS ....................................................................... 17/5

GENERAL SPECIFICATIONS ........................................................ 17/5
SEALANTS ............................................................................ 17/6
EMISSION CONTROL ................................................................. 17/7

COMPONENT LAYOUT ............................................................. 17/7
CATALYTIC CONVERTER .............................................................. 17/9

REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/10
INSPECTION ............................................................................
OXYGEN SENSOR CHECK ..........................................................
T
Oxygen sensor (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17/12
17/12
17/12
AF
Oxygen sensor (rear — *if fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/13
ENGINE COOLANT TEMPERATURE SENSOR CHECK .......................... 17/15
PURGE SOLENOID VALVE ASSY CHECK ......................................... 17/16
EMISSION CONTROL<MPI> ......................................................... 17/17

PARTS LOCATION ................................................................... 17/17
S4P MPI (CFE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/17
R
AUTO CRUISE CONTROL ............................................................ 17/18

D

CRUISE CONTROL ................................................................... 17/19
WARNING LIGHT .................................................................... 17/19
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/19
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/20
AUTO CRUISE CONTROL ............................................................ 17/21

INSPECTION ............................................................................ 17/22

INPUT INSPECTION TABLE ......................................................... 17/22
DIAGNOSIS FUNCTION ............................................................... 17/24
ON-VEHICLE SERVICE ................................................................. 17/25

AUTO-SPEED (CRUISE) CONTROL ................................................ 17/25
TO ACTIVATE ......................................................................... 17/25
TO INCREASE THE SET SPEED ..................................................... 17/25
TO REDUCE THE SET SPEED ....................................................... 17/26
TO ACCELERATE FOR PASSING ................................................... 17/26
TO DEACTIVATE ..................................................................... 17/27

/2 Content
TO RESUME THE SET SPEED ....................................................... 17/27
INSPECTION ............................................................................ 17/28

AUTO-CRUISE CONTROL SWITCH CHECK ...................................... 17/28
STOP LAMP SWITCH CHECK ...................................................... 17/29
T
AF
R
D

Content /3
NOTE
T
AF
R
D

GENERAL SPECIFICATIONS WCH017GINFO12001
SPECIFICATIONS
The emission control system consists of the following subsystems:
• Crankcase emission control system
• Evaporative emission control system
• Exhaust emission control system
Item Name Specification

Crankcase emission control Positive crankcase ventilation Restrictor
system (Purpose: HC reduction)
Evaporative emission control Canister Equipped
system Purge control solenoid valve ON/OFF type solenoid valve
(Purpose: HC reduction)
Exhaust emission control sys- Air-fuel ratio control device-MPI Oxygen sensor feedback type
tem system (Purpose: CO, HC, NOx reduction)
Catalytic converter Monolith type
(Purpose: CO, HC, NOx reduction)
SPECIAL TOOLS
TOOLS
T WCH017STOOL12001
AF
interface (VCI)
R
DOIMC35BR11039
D

CD
DOIMC35BR11042

connector; 1 m) VCI
DOIMC35BR11041

USB cable (1.8 m)
PC and VCI
DOIMC35BR11046

SPECIFICATIONS /5

DOIMC35BR11045

Ethernet cable
ing to VCI
DOIMC35BR11040

Cable keeper
T
cable messy
DOIMC35BR11043
AF
R
DOIMC35BR11044
D
DOIMC35BR11047
GENERAL SPECIFICATIONS
Oxygen sensor Zirconia type
Coolant temperature sensor Thermistor type
Evaporative solenoid valve Duty cycle type
Resistance

/6 SPECIFICATIONS

At 20 °C (68 °F) Terminal 2 → Connect terminal 3 2.2-2.7 kΩ
Terminal 4 → Connect terminal 1 5.7-6.6 kΩ
At 80 °C (176 °F) Terminal 2 → Connect terminal 3 0.3-0.34 kΩ
Terminal 4 → Connect terminal 1 0.59-0.652 kΩ
Evaporative solenoid valve (Tank purge valve)
Resistance
At 23 °C (73.4 °F) 26 Ω ± 1.8 Ω
Oxygen sensor
Resistance
At 23 °C (73.4 °F) ± 5 °C (41 °F) 4.5 Ω ± 0.5 Ω
Purge control solenoid valve coil resistance at 20 °C (68 °F) 36-44 Ω
M/T ⇒ 900 r/min± 100 r/min
Engine idle speed MPI P/N ⇒ 850 r/min± 100 r/min
D ⇒ 750 r/min ± 100 r/min
Items
Oxygen sensor (front)
T Standard value
2.5-2.9 kgm (25-29 Nm, 18.08-20.98 ft.lbs)
3.5-4.5 kgm (35-45 Nm, 25.32-32.55 ft.lbs)
AF
Oxygen sensor (rear) 4.0-5.0 kgm (40-50 Nm, 28.93-36.16 ft.lbs)
SEALANTS
Items Specified sealant Quantity
Coolant temperature sensor 3M Nut Locking Part No.4171 or As required
R
threaded part equivalent

D

EMISSION CONTROL /7
EMISSION CONTROL WCH017SASSY12001
COMPONENT LAYOUT
T
AF
R
D
DOIQC017R12001

/8 EMISSION CONTROL
A B
DOINC017R11001 DOINC017R11003
C D
T
AF
E
R
D
DOIQC017R12002
Symbol Name Symbol Name

A Front oxygen sensor D Purge control valve
B Coolant temperature sensor E Canister
C Tmap

CATALYTIC CONVERTER /9
CATALYTIC CONVERTER WCH017SASSY12003
GENERAL INFORMATION
The three-way catalytic converter, together with the closed loop air-fuel ratio control based on oxygen
sensor signal, oxidizes carbon monoxides (CO) and hydrocarbons (HC) and reduces nitrogen oxides
(NOx).
When the mixture is controlled at stoichiometric air-fuel ratio the three-way catalytic converter
provides the highest purification against the constituents, namely, CO, HC and NOx.
T
AF
R
D

/ 10 CATALYTIC CONVERTER
T
AF
R
D
DOIQC017R12005

CATALYTIC CONVERTER / 11
Pre-removal and installation

• Turbo charger (Refer to page – WCH015SASSY11012).
• Exhaust manifold (Refer to page – WCH015SASSY11011)
Removal steps
1. Oxygen sensor front
2. Heatshield turbo lower
3. Heatshield turbo upper
4. Gasket catalytic converter
5. Assy catalytic converter
6. Bracket catalytic converter
7. Gasket exhaust pipe front
8. *Oxygen sensor rear
9. Front Exhaust Pipe
10. Main Mufler
T1: 0.4 - 0.6 kgm (4 - 6 Nm, 2.89 - 4.34 ft.lbs)
T2: 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T
T5: 3.5 - 4.5 kgm (35 - 45 Nm, 25.32 - 32.55 ft.lbs)
T6: 4.0 - 5.0 kgm (40 - 50 Nm, 28.93 - 36.16 ft.lbs)
AF
NOTE
* If fitted
R
D

/ 12 INSPECTION

1. Remove the oxygen sensor by using the spe-
cial tool (MD998770)
Symbol Description
A Oxygen sensor (front)
C Catalylic converter
DOINC015R11022
OXYGEN SENSOR CHECK

1. Disconnect the oxygen sensor connector and
connect the special tool (test harness) to the
T connector on the oxygen sensor side.
Symbol Description
AF
A Oxygen sensor (front)
B Equipment side connector
DOINC017R11010
2. Make sure the continuity as follow

Standard value:
(at 23 °C (73.4 °F) ± 5 °C (41 °F))
R
Terminal No. Standard value

Terminal No.1 connect 4.5 Ω ± 0.5 Ω
→terminal No.3
D
Symbol Description
A Oxygen sensor equipment
side connector
B Blue (No.3 terminal)
DOIGE17BR03004 R Red (No.1 terminal)
3. If there is no continuity , replace the oxygen

sensor.
4. Warm up the engine until engine coolant
is80 °C (176 °F) or higher.

INSPECTION / 13
5. Use the jumper wire to connect terminal 1

(red clip) of the oxygen sensor connector to
the battery (+) terminal and terminal 3 (blue
clip) to the battery (-) terminal.
Symbol Description
A Jumper wire
B Black
C Blue
R Red
E White
DOIGE17BR03005
Caution
Be careful when connecting the jumper wire.
Incorrect connection can damage the oxygen
sensor.
6. Connect a digital voltage meter between
terminal 2 (black clip) and terminal 4 (white
clip).
7. While repeatedly racing the engine , measure
T the oxygen sensor output voltage.

Standard value:
AF
Engine Oxygen sensor output
voltage
When racing 0.8-0.92 V
the engine
Remarks If you make air/fuel ratio
rich by racing the engine
R
repeatedly, a normal oxy-

gen sensor will output a
voltage of 0.8-0.92 V
8. If the sensor is defective , replace the oxygen
D
sensor.
NOTE
For removal and installation of the oxygen
sensor, refer to Chassis Manual — GROUP
15–Exhaust Pipe and Main Muffler.
Oxygen sensor (rear — *if fitted)
1. Disconnect the oxygen sensor connector and
connect the special tool (test harness) to the
connector of the oxygen sensor side.
Symbol Description
A Rear oxygen sensor
B Equipment side connector
DOINC017R11012

/ 14 INSPECTION
2. Make sure that the specified resistance (4.5

Ω ± 0.5 Ω at 23 °C (73.4 °F) ± 5 °C (41 °F))
between terminal 1 (red clip of special tool)
and terminal 3 (blue clip of special tool) at
the oxygen sensor connector.
Symbol Description
A Oxygen sensor equipment side
connector
B Blue
R Red
DOIGE17BR03004
3. If the resistance value is out from specifica-
tion, replace the oxygen sensor.
4. Use the jumper wire to connect terminal 1
(red clip) of the oxygen sensor connector to
the battery (+) terminal and terminal 3 (blue
clip) to the battery (-) terminal.
Symbol Description
T A
B
C
Jumper wire
Black
Blue
AF
R Red
E White
DOIGE17BR03005
Caution
Be careful when connecting the jumper wire.
Incorrect connection can damage the oxygen
R
sensor.
5. Connect a digital voltage meter between
terminal 2 (black clip) and terminal 4 (white
clip).
D
6. Measure the oxygen sensor output voltage.

Standard value:
Oxygen sensor output

Engine
voltage
Ignition 'ON' 278.18 mv
7. If the voltage value of sensor is out from
specification, replace the oxygen sensor.

INSPECTION / 15
ENGINE COOLANT TEMPERATURE

SENSOR CHECK
CAUTION
stalling.
1. Use special tool (MD998770) to remove the
engine coolant temperature sensor (A).
DOIGE17BR03001
2. With temperature sensing portion of engine

coolant temperature sensor immersed in hot
water, check resistance.
Standard value:
(at 20 °C (68 °F))
T Terminal No.2 connect

→terminal No.3
2.2-2.7 kΩ
AF
Terminal No.4 connect 5.7-6.6 kΩ
→terminal No.1
DOIIE17BR9006 Standard value:
(at 80 °C (176 °F))

R

→terminal No.3
D
→terminal No.1
value greatly, replace the sensor.
4. Apply sealant to threaded portion.
Specified sealant :
3M Nut Locking No. 4171 or equivalent
5. Use special tool (MD998770) to install the

coolant temperature sensor and tighten it
Specified torque : 2.5-2.9 kgm (25-29 Nm,
18.08-20.98 ft.lbs)
DOIGE11AR03039

/ 16 INSPECTION
PURGE SOLENOID VALVE ASSY CHECK

CAUTION
stalling.
Symbol Description
A Solenoid valve assy
B Breather assy
C Canister
1. Remove the solenoid valve assy (A).
DOIGE11AR06230
2. Check the solenoid valve assy inductance

value.
Symbol Description
A Tank purge valve equipment
side connector
B Blue
T R Red
Standard value:
AF
(at 23 °C (73.4 °F) at frequency 0-20 Hz)

DOIGE17BR03007
Terminal No.1 connect 50mH approx
→terminal No.2
3. The figure shows how the resistance values

R
are measured. The test harness : MB 991223

and jumper wire are used to connect the
connector of tank purge valve.
D
Symbol Description
A Tank purge valve equipment
side connector
B Blue
R Red
To measure the resistance continuity.
DOIGE17BR03008
Standard value:
(at 23 °C (73.4 °F) )

Terminal No.1 connect 26 Ω ± 1.8 Ω
→terminal No.2
4. If there is no continuity, replace the tank

purge valve.

EMISSION CONTROL<MPI> / 17
EMISSION CONTROL<MPI> WCH017SPROC12003
PARTS LOCATION
S4P MPI (CFE)
T
AF
R
DOIQC017R12003
D
– Sealant
1. Oxygen sensor (front)
3. Tank Purge solenoid valve
4. Purge solenoid valve
T1 : 3.5 - 4.5 kgm (35 - 45 Nm, 25.32 - 32.55 ft.lbs)
T2 : 2.5 - 2.9 kgm (25 - 29 Nm, 18.08 - 20.98 ft.lbs)
T3 : 4.0 - 5.0 kgm (40 - 50 Nm, 28.93 - 36.16 ft.lbs)

/ 18 AUTO CRUISE CONTROL
AUTO CRUISE CONTROL WCH017SASSY12005
T
AF
R
DOINC017R09008
D
CAUTION : SRS
Before remove of air bag module and clock spring, refer to GROUP 52B - SRS Service Precautions
and Air Bag Module and Clock spring.
Removal steps
1. Cruise control switch
2. Horn pad
4. Steering wheel
5. Clock spring
T1: 3.9 kgm (39 Nm, 28.21 ft.lbs)

GENERAL SPECIFICATIONS / 19
WCH017GINFO12003
CRUISE CONTROL
Makes it possible to maintain a speed selection
by the driver.
WARNING LIGHT
A warning light on the meter combination in-
forms the driver of the status of the cruise con-
trol.
Colour Status
Amber light: cruise control is in standby
mode.
Green light: cruise control in operation.
Symbol Description
A Warning light indicator
DOIQC017R12006
INSPECTION
T To control these functions, the ECU receives the

following signals on the following tracks:
AF
Connector Number Pin number name
Pin number : 53 : Cruise control — ACC SET/RESUME
Pin number : 54 : Cruise control switch — SET/COAST
Pin number : 57 : Cruise control switch — CANCEL
Pin number : 45 : Cruise control switch — ON/OFF
R
Pin number : 32 : Pedal potentiometer 1 feed

Pin number : 51 : Pedal potentiometer 2 feed
Connector C-10
Pin number : 31 : Pedal potentiometer 1 earth
D
Pin number : 50 : Pedal potentiometer 2 earth

Pin number : 47 : Pedal potentiometer 1 signal
Pin number : 48 : Pedal potentiometer 2 signal
Pin number : 37 : CAN interface (Low)
Pin number : 38 : CAN interface (High)
The ECU (EMS 700) sends the following signals
to TCU.
1. Cruise control switch setting at the steering.
2. The brake light signal.
The ECU (EMS 700) receives:
• Receives signal from the accelerator pedal
sensor
• Receives signal from the brake light switch
• Receives signals from the cruise control
switch
• Receives signal from the automatic transmis-
sion unit.
• Control the motorised throttle unit.

/ 20 GENERAL SPECIFICATIONS
NOTE
Using these signals, the ECU (EMS 700) controls
the motor-driven throttle unit to maintain the
set speed in the case of cruise control.
GENERAL INFORMATION
Items Description
• Cruise control switch
setting at the steering.
The ECU unit:
• Sends the depressed
brake pedal signal
• Sends the gear en-
The automatic
gaged signal
transmission unit:
• The engine speed
The cruise control • Displays the reference
switch value (cruise control)
The cruise control switch must be ON in order
for the cruise control switch to function. Once
the ACC Set/Resume is pressed (to increase the
T current speed), the accelerator pedal poten-

tiometer are pressed until the desired speed is
achieved. Reversibly, the Set/Coast is used to de-
AF
crease the current speed. Therefore, the acceler-
ator pedal potentiometer is released until the
current speed is decreased. The following control
are fitted:
• Speed set switch (Steering wheel switches
that can be used to adjust the desired speed,
cancel the function or recall the stored
R
speed).
• Accelerator pedal potentiometer that are
used to control the injection and the brake
D
lights.
NOTE
The accelerator pedal must incorporate a point
of resistance at the end of its travel.

AUTO CRUISE CONTROL / 21
AUTO CRUISE CONTROL WCH017SASSY12007
T
AF
R
DOINC017R09008
D
CAUTION : SRS
Before remove of air bag module and clock spring, refer to GROUP 52B - SRS Service Precautions
and Air Bag Module and Clock spring.
Removal steps
2. Horn pad
4. Steering wheel
5. Clock spring
T1: 3.9 kgm (39 Nm, 28.21 ft.lbs)

/ 22 INSPECTION
INPUT INSPECTION TABLE

Input operation Operation judgement
MAIN switch ON EMS judges that SET switch is ON
ACC / RESUME switch ON EMS judges that RESUME switch is ON
Stop lamp switch (ON when brake
EMS judges that stop lamp switch is ON
pedal depressed)
ACC / RESUME switch ON EMS judges that set and (+) switch is ON
COAST / SET switch ON EMS judges that set and (-) switch is ON
EMS judges that vehicle speed is 38 km/h (23.61 mph) or
higher
Vehicle speed signal
EMS judges that vehicle speed is lower than 38 km/h (23.61
mph)
Inhibitor switch <A/T> (ON when se-
EMS judges that inhibitor switch <A/T> is ON
lect lever in N range)
CANCEL switch ON EMS judges that CANCEL switch is ON
T
EMS judges that motorised throttle unit sensor signal voltage:
Pedal foot up:
Value ⇒ 0.72 V
Connector: C-10, Pin No.: 48
AF
Max. = 0.8 V
Min. = 0.7 V
Pedal foot up:
Value ⇒ 0.36 V
Max. = 0.425 V
Motorised throttle unit sensor signal Min. = 0.325 V
R
Pedal foot up:

Value ⇒ 4.43 V
Max. = 4.6 V
Min. = 4.2 V
D
Pedal foot up:

Value ⇒ 2.22 V
Max. = 2.4 V
Min. = 2 V
NOTE
The voltage measurement should be in the range as shown below. Otherwise, motorised throttle unit
will not work properly

INSPECTION / 23
Voltage measurement should be connected

between:
Symbol Description
A ECU (EMS 700)
Connector C-10.
B Pin number: 48 – Pedal potentiomet-
er 2 signal
C Read the voltmeter
Connector C-21.
D Pin number: 2 – Accelerator pedal
sensor (Earth)
DOIJC017R9032
Connector C-10.
E
Pin number: 5 – ECU (Earth)
Connector C-10.
F
Pin number: 50 – ECU (Earth)
Voltage measurement should be connected
between:
Symbol Description
T A ECU (EMS 700)

Connector C-10.
AF
B1 Pin number: 47 – Pedal potentiomet-
er 1 signal
C Read the voltmeter
Connector C-21.
D Pin number: 3 — Accelerator pedal
sensor (Earth)
R
DOIJC017R9033
Connector C-10.
E
Pin number: 5 — ECU (Earth)
Connector C-10.
F
Pin number: 31 — ECU (Earth)
D

/ 24 DIAGNOSIS FUNCTION
DIAGNOSIS FUNCTION WCH017SPROC12005

PADT-II
Symbol Description
A Wireless method
B Cable method
CAUTION
or disconnecting the PADT-II
T

AF
from the battery (–) terminal for 10
Fault Code Chart
R
Fault Diagnosis Items Check Items

Code No. (Remedy)
P0564 Criuse control
D
device diagnosis
–ON/OFF
P0567 Cruise control • Check cruise
device diagnosis – control switch
resume • Check the
P0568 Cruise control harness of
device diagnosis – cruise control
accelarate switch
P0569 Cruise control • Check the igni-
device diagnosis tion system
–deacclerate
P0585 Cruise control
device diagnosis

AUTO-SPEED (CRUISE) CONTROL

The desire speed [ 38 km/h (23.61 mph) above]
can be set and held without operating the accel-
erator pedal.
This feature is useful for highway driving.
TO ACTIVATE
1. Push main switch labeled as 'ON-OFF' at
cruise control lever (once push, amber colour
appears on the meter combination's screen).
2. Push down to set and green colour will ap-
pear.
Description
Switch cruise control:
• ACC / Resume switch — Set and (+)
switch
• Coast / Set switch — Set and (-) switch
T
DOINC017R09005
TO INCREASE THE SET SPEED

AF
There are 2 ways to increase the set speed.
1. ”ACC / RESUME” switch
Pull up the cruise control lever labelled as
”ACC/RES” switch and hold it until you reach
the higher speed you want. Release the
switch when the desired speed is reached.
To increase your speed in small amounts, just
R
pull up the ”ACC / RE” switch for less than

0.5 seconds and release it. Each time you
operate this switch, your vehicle will go 1
D
DOIGC017R03004 km/h (0.62 mph) faster.

2. ACCELERATOR PEDAL
Press ”CANCEL” switch first then use the ac-
celerator pedal to increase the vehicle's speed
and when the desired speed is reached, pull
down the switch.
DOIGC017R03005

TO REDUCE THE SET SPEED

There are 2 ways to decrease the set speed.
1. 'COAST / SET' switch
Pull down the cruise control lever 'COAST /
SET' switch and hold it until you reach the
lower speed you want. Released the switch
when the desired speed is reached.
To decrease your speed in small amounts,
just pull down the 'COAST / SET' switch for
less than 0.5 seconds and release it. Each time
you operate the switch, your vehicle speed
DOIGC017R03006
will reduce by 1 km/h (0.62 mph)
2. BRAKE PEDAL
Use the brake pedal to reduce the vehicle's
speed and, when the desired speed is
reached, pull down the ”COAST / SET” switch.
T
AF
DOIGC017R03007
TO ACCELERATE FOR PASSING

Depress the accelerator pedal in the normal way.
R
When the pedal is released, your vehicle will re-

turn to the set speed.
Symbol Description
D
A Depress
B Released
C Cruise control switch
DOINC017R09006

TO DEACTIVATE
Pull ”CANCEL” switch at the lever or press OFF
the switch cruise control.
The auto speed control can be deactivated
automatically in any of the following ways.
1. By slightly tapping the brake pedal or depress-
ing it to reduce the speed.
2. By moving the selector lever to the ”N” (for
automatic transmission model).
Description
Switch cruise control — On / Off
DOINC017R09005
• ACC / Resume switch — Set and (+) switch
TO RESUME THE SET SPEED

If the vehicle speed remains 38 km/h (23.61 mph)
or higher when the auto cruise speed control is
T deactivated by operating the push ”CANCEL”

switch or by any one of the (1) to (3) conditions
noted above, the previously set speed can be
AF
automatically resumed by pulling the ”ACC / Res”
lever towards you.
Under any of the following conditions, however,
operating the ”RESUME” switch does not allow
you to resume the previously set speed. In these
DOIGC017R03009 situations, start the speed setting procedure over
“ACC / Res”.
R
1. Switch “CANCEL” was pressed.
Symbol Description
D
A ”CANCEL”
B ”ACC / Res”
2. The engine has stopped.
Symbol Description
Engine stop (Key lock posi-
A
tion)
DOINC017R09007

/ 28 INSPECTION
T
AF
DOINC017R09017
AUTO-CRUISE CONTROL SWITCH CHECK

R
TO ACTIVATE
1. Operate the switches and check for continuitiy between the terminals
D
Pin No Description
1 ACC SET / RESUME
3 SET-COAST
4 CANCEL
5 MAIN SWITCH
Terminal ⇒ Switch position Terminal No. Continuity Check
Push the main switch lever. Terminal No. 9 – pin connect-
ACC SET / RESUME or: D-18 connect ⇒ Terminal No. 1 – pin connector: D-18
OK: Continuity
Push the ACC /RESUME switch lever Terminal No. 9 – pin
connector: D-18 connect ⇒ Terminal No. 3 – pin connector:
SET/COAST
D-18
OK: Continuity
Push the COAST / SET switch lever to ON. Terminal No.
9 – pin connector: D-18 connect ⇒ Terminal No. 4 – pin
CANCEL
connector: D-18
OK: Continuity

INSPECTION / 29
Terminal ⇒ Switch position Terminal No. Continuity Check

Push the CANCEL switch lever to ON. Terminal No. 9 –
pin connector: D-18 connect ⇒ Terminal No. 5 – pin con-
MAIN SWITCH
nector: D-18
OK: Continuity
2. Push the main switch leverto ON. When the battery (+) side is connected to terminal 9–pin con-
nector: D-18 and the (-) side is connected to terminal 1– pin connector: D-18, check if there are
output voltage between these two terminals.
Next, when the main switch is turned to OFF, check if the output voltage between these two ter-
minals becomes 0 V .
Pin No Description
1 ACC SET / RESUME
3 SET/COAST
4 CANCEL
5 MAIN SWITCH
3. Measure the resistance between the terminals when each of the SET, RESUME and CANCEL switches
is pressed. If the values measured follows exactly the standard resistance values as stated in the
table below, then there will be no problem on the cruise control switch.
Pin No
T
Resistance between terminals Pin No.
Terminal Pin No. 9 ⇒ connect
AF
ACC SET/ RESUME Approx. 1.5 kΩ ± 1%
⇒ Terminal Pin No. 1
SET/COAST Approx. 1.5 kΩ ± 1%
CANCEL Approx. 1.5 kΩ ± 1%
R
MAIN SWITCH Approx. 1.5 kΩ ± 1%

STOP LAMP SWITCH CHECK
D
1. Connect a circuit tester to the stop lamp

switch, and check whether there is continuity
when the plunger of stop lamp switch is
pushed in or when it is released. The stop
lamp switch is in good condition if there is
no continuity when the plunger is pushed in
to a depth of within 4 mm (0.16 in) ± 0.5 mm
(0.02 in) from the outer case edge surface.
Reversibly, continuity exists when the plunger
is released.
DOIKC017R03023
Symbol Description
4 mm (0.16 in) ± 0.5 mm (0.02
A
in)
B No continuity
C Continuity

/ 30 INSPECTION
NOTE
T
AF
R
D

EMISSION CONTROL<IAFM+> 17
Content /1
17 EMISSION CONTROL<IAFM+>
SPECIFICATIONS ..................................................................... 17/2
EMISSION CONTROL DEVICE REFERENCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17/2
SPECIAL TOOLS ........................................................................ 17/2

COMPONENT LAYOUT ............................................................. 17/5
VACUUM HOSE PIPING DIAGRAM ............................................... 17/7
CATALYTIC CONVERTER .............................................................. 17/9

DIAGNOSIS FUNCTION ............................................................... 17/12

AUTO-SPEED (CRUISE) CONTROL ................................................ 17/13
T
TO ACTIVATE .........................................................................
TO INCREASE THE SET SPEED .....................................................
TO REDUCE THE SET SPEED .......................................................
17/13
17/13
17/14
AF
TO ACCELERATE FOR PASSING ................................................... 17/14
TO DEACTIVATE ..................................................................... 17/15
TO RESUME THE SET SPEED ....................................................... 17/15
R
D

GENERAL SPECIFICATIONS WCH017GINFO12002
SPECIFICATIONS
The emission control system consists of the following subsystems:
• Crankcase emission control system
• Evaporative emission control system
• Exhaust emission control system
Item Name Specification

Crankcase emission control Positive crankcase ventilation Restrictor
system (Purpose: HC reduction)
Evaporative emission control Canister Equipped
system Purge control solenoid valve ON/OFF type solenoid valve
(Purpose: HC reduction)
Exhaust emission control sys- Air-fuel ratio control device-MPI Oxygen sensor feedback type
tem system (Purpose: CO, HC, NOx reduction)
Catalytic converter Monolith type
(Purpose: CO, HC, NOx reduction)
EMISSION CONTROL DEVICE REFERENCE TABLE
Related part
Evaporative
emission control
trol system
T
Air/fuel ratio con- Catalytic
converter
Reference page
AF
system
Purge control
X
solenoid valve
GROUP 13A
MPI system
X X
component
Catalytic converter Refer to pageW-
X
R
CH017SASSY040
D
Purge control solenoid valve coil resistance

36-44 Ω
at 20 °C (68 °F)
Item Standard valve
M/T ⇒ 900 r/min± 100 r/min
Engine idle speed MPI P/N ⇒ 850 r/min± 100 r/min
D ⇒ 750 r/min ± 100 r/min
SPECIAL TOOLS WCH017STOOL12001
TOOLS
interface (VCI)
DOIMC35BR11039

SPECIAL TOOLS /3

CD
DOIMC35BR11042

connector; 1 m) VCI
DOIMC35BR11041

USB cable (1.8 m)
T
PC and VCI
DOIMC35BR11046
AF
R
DOIMC35BR11045
D

Ethernet cable
ing to VCI
DOIMC35BR11040

Cable keeper
cable messy
DOIMC35BR11043

DOIMC35BR11044

/4 SPECIAL TOOLS
DOIMC35BR11047
T
AF
R
D

EMISSION CONTROL /5
EMISSION CONTROL WCH017SASSY12002
COMPONENT LAYOUT
T
AF
R
D
DOIMC017R07007

/6 EMISSION CONTROL
A B
DOIMC017R07003 DOIMC017R07004
C D
T
AF
E
R
D
DOIQC017R12002
Symbol Name Symbol Name

A Solenoid valve D Oxygen sensor front
B Tmap E Canister
C Coolant temperature sensor
NOTE :
Please check the item in data display tab function by using PADT-07

EMISSION CONTROL /7
VACUUM HOSE PIPING DIAGRAM WCH017SPECS12002
T
AF
R
D
DOIMC017R07008

/8 EMISSION CONTROL
Symbol Description
A Evaporative valve
B Mat map sensor
C Air cleaner
D Coolant temperature
E Oxygen sensor front
F Oxygen sensor rear
T
AF
R
D

CATALYTIC CONVERTER /9
CATALYTIC CONVERTER WCH017SASSY12004
GENERAL INFORMATION
The three-way catalytic converter, together with the closed loop air-fuel ratio control based on oxygen
sensor signal, oxidizes carbon monoxides (CO) and hydrocarbons (HC) and reduces nitrogen oxides
(NOx).
When the mixture is controlled at stoichiometric air-fuel ratio the three-way catalytic converter
provides the highest purification against the constituents, namely, CO, HC and NOx.
T
AF
R
D

/ 10 CATALYTIC CONVERTER
T
AF
R
D
DOIQC017R12007

CATALYTIC CONVERTER / 11
Removal steps
2. Heatshield exhaust manifold
3. Exhaust manifold
4. Gasket catalytic converter
5. Assy catalytic converter
6. Bracket catalytic converter
7. Gasket exhaust pipe front
8. * Rear oxygen sensor
10. Main mufler
11. Front floor heat proctector
12. Rear floor heat proctector
T1: 3.4 - 4.4 kgm (34 - 44 Nm, 24.59 - 31.83 ft.lbs)
T2: 3.3 - 4.9 kgm (33 - 49 Nm, 23.87 - 35.44 ft.lbs)
T3: 1.0 - 1.5 kgm (10 - 15 Nm, 7.23 - 10.85 ft.lbs)
T4: 0.4 - 0.6 kgm (4 - 6 Nm, 2.89 - 4.34 ft.lbs)
T5: 4.0 - 5.0 kgm (40 - 50 Nm, 28.93 - 36.16 ft.lbs)
T
AF
R
D

/ 12 DIAGNOSIS FUNCTION
DIAGNOSIS FUNCTION WCH017SPROC12005

PADT-II
Symbol Description
A Wireless method
B Cable method
CAUTION
or disconnecting the PADT-II
T

AF
from the battery (–) terminal for 10
Fault Code Chart
R
Fault Diagnosis Items Check Items

Code No. (Remedy)
P0564 Criuse control
D
device diagnosis
–ON/OFF
P0567 Cruise control • Check cruise
device diagnosis – control switch
resume • Check the
P0568 Cruise control harness of
device diagnosis – cruise control
accelarate switch
P0569 Cruise control • Check the igni-
device diagnosis tion system
–deacclerate
P0585 Cruise control
device diagnosis

AUTO-SPEED (CRUISE) CONTROL

The desire speed [ 38 km/h (23.61 mph) above]
can be set and held without operating the accel-
erator pedal.
This feature is useful for highway driving.
TO ACTIVATE
1. Push main switch labeled as 'ON-OFF' at
cruise control lever (once push, amber colour
appears on the meter combination's screen).
2. Push down to set and green colour will ap-
pear.
Description
• ACC / Resume switch — Set and (+)
switch
T
DOINC017R09005
TO INCREASE THE SET SPEED

AF
There are 2 ways to increase the set speed.
1. ”ACC / RESUME” switch
Pull up the cruise control lever labelled as
”ACC/RES” switch and hold it until you reach
the higher speed you want. Release the
switch when the desired speed is reached.
To increase your speed in small amounts, just
R
pull up the ”ACC / RE” switch for less than

0.5 seconds and release it. Each time you
operate this switch, your vehicle will go 1
D
DOIGC017R03004 km/h (0.62 mph) faster.

2. ACCELERATOR PEDAL
Press ”CANCEL” switch first then use the ac-
celerator pedal to increase the vehicle's speed
and when the desired speed is reached, pull
down the switch.
DOIGC017R03005

TO REDUCE THE SET SPEED

There are 2 ways to decrease the set speed.
1. 'COAST / SET' switch
Pull down the cruise control lever 'COAST /
SET' switch and hold it until you reach the
lower speed you want. Released the switch
when the desired speed is reached.
To decrease your speed in small amounts,
just pull down the 'COAST / SET' switch for
less than 0.5 seconds and release it. Each time
you operate the switch, your vehicle speed
DOIGC017R03006
will reduce by 1 km/h (0.62 mph)
2. BRAKE PEDAL
Use the brake pedal to reduce the vehicle's
speed and, when the desired speed is
reached, pull down the ”COAST / SET” switch.
T
AF
DOIGC017R03007
TO ACCELERATE FOR PASSING

Depress the accelerator pedal in the normal way.
R
When the pedal is released, your vehicle will re-

turn to the set speed.
Symbol Description
D
A Depress
B Released
C Cruise control switch
DOINC017R09006

TO DEACTIVATE
Pull ”CANCEL” switch at the lever or press OFF
the switch cruise control.
The auto speed control can be deactivated
automatically in any of the following ways.
1. By slightly tapping the brake pedal or depress-
ing it to reduce the speed.
2. By moving the selector lever to the ”N” (for
automatic transmission model).
Description
Switch cruise control — On / Off
DOINC017R09005
• ACC / Resume switch — Set and (+) switch
TO RESUME THE SET SPEED

If the vehicle speed remains 38 km/h (23.61 mph)
or higher when the auto cruise speed control is
T deactivated by operating the push ”CANCEL”

switch or by any one of the (1) to (3) conditions
noted above, the previously set speed can be
AF
automatically resumed by pulling the ”ACC / Res”
lever towards you.
Under any of the following conditions, however,
operating the ”RESUME” switch does not allow
you to resume the previously set speed. In these
DOIGC017R03009 situations, start the speed setting procedure over
“ACC / Res”.
R
1. Switch “CANCEL” was pressed.
Symbol Description
D
A ”CANCEL”
B ”ACC / Res”
2. The engine has stopped.
Symbol Description
Engine stop (Key lock posi-
A
tion)
DOINC017R09007

NOTE
T
AF
R
D

CLUTCH 21
Content /1
21 CLUTCH
GENERAL INFORMATION ............................................................ 21/2
CONSTRUCTION DIAGRAM ....................................................... 21/2
SPECIFICATIONS ....................................................................... 21/2

LUBRICANTS ......................................................................... 21/3
SPECIAL TOOLS (5MTT200A) ....................................................... 21/3

TOOLS ................................................................................ 21/3
TROUBLESHOOTING ................................................................. 21/3

SYMPTOM ............................................................................ 21/3

CLUTCH PEDAL INSPECTION AND ADJUSTMENT ............................. 21/4
BLEEDING ............................................................................. 21/5
CLUTCH FLUID ........................................................................ 21/5
CLUTCH PEDAL .......................................................................

REMOVAL AND INSTALLATION ..................................................
DISASSEMBLY AND REASSEMBLY ...............................................
T 21/7
21/7
21/8
AF
CLUTCH CONTROL ................................................................... 21/9
CLUTCH MASTER CYLINDER ....................................................... 21/11

DISASSEMBLY AND REASSEMBLY ............................................... 21/11
R
CLUTCH COVER AND DISC .......................................................... 21/13

D
CLUTCH COVER AND DISC (5MTT200A) .......................................... 21/14

CLUTCH COVER ASSEMBLY AND CLUTCH DISC REMOVAL ................. 21/14
SERVICE POINTS OF INSTALLATION .............................................. 21/14
INSPECTION .......................................................................... 21/16
CLUTCH COVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21/16
CLUTCH DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21/16
CONCENTRIC SLAVE CYLINDER(CSC) .............................................. 21/17

CONCENTRIC SLAVE CYLINDER (CSC) ............................................. 21/18

CLUTCH ................................................................................. 21/19

INSPECTION .......................................................................... 21/19
CONCENTRIC SLAVE CYLINDER ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21/19
CONCENTRIC SLAVE CYLINDER,HOSE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21/20

21 CLUTCH
The clutch is a dry single-disc with diaphragm type hydraulic pressure which used for the clutch con-
trol.The clutch shares brake fluid reservoir with the brake system.
CONSTRUCTION DIAGRAM
T
AF
R
D
DOIQC021R11001
Removal steps
1. Clutch tube assembly
2. To brake fluid reservior
3. Clutch master cylinder
4. Clutch pedal assembly
5. Clutch release cylinder
6. Transmission assembly
Clutch operating method Hydraulic type
Clutch master cylinder I.D. 34.5 mm (1.36 in)

CLUTCH 21
SPECIAL TOOLS (5MTT200A) /3
Clutch pedal stroke 130 mm (5.12 in)
Clutch pedal free play 2 mm (0.079 in)
Distance between the clutch pedal and the toe-
271 mm (10.67 in) or more
board when the clutch is disengaged
Clutch disc type Dry single plate type
Clutch disc facing diameter OD x ID mm 200
Clutch cover type Diaphragm spring type
Clutch cover setting load N (Ib) 4,320 ± 350 (N)
Clutch fluid Brake fluid DOT4
LUBRICANTS
Items Specified lubricants Quantity
Clutch fluid Brake fluid DOT4
Push rod assembly
Rubber grease As required
Boot
Release cylinder push rod
T
PROTON GENUINE grease
AF
SPECIAL TOOLS (5MTT200A) WCH021STOOL11001
TOOLS
R
EZT 0044 Flywheel stopper. • To lock flywheel.

D
DOIME11AR11051
• To hold clutch
Clutch plate In-
EZT 0045 plate during install-
staller
ation.
DOIMT21AR11007
TROUBLESHOOTING WCH021TSHOT11001
SYMPTOM
Excessive clutch pedal free play Adjust clutch pedal
Insufficient disengagement of Insufficient clutch fluid Refill clutch fluid
clutch Fluid leaks, air mixed in system or Repair, replace or air bleed
clogging

21 CLUTCH
/4 ON-VEHICLE SERVICE

Insufficient pedal free play Adjust clutch pedal play
Burned, worn or oil-soaked fa- Replacing disc assembly and
Clutch slipping
cings correct cause of contamination
Weak or broken pressure spring Replace cover assembly
Insufficiently lubricated joint of Lubricate
Noise when clutch is disengaged clutch cable and pedal arm
while engine is running Malfunction of clutch release Replace
bearing
Insufficiently lubricated pedal Lubricate
shaft
Unsmooth pedal operation Insufficiently lubricated clutch Lubricate or replace
cable
Deteriorated return spring Replace
Worn or damaged disc assembly Replace disc assembly
Oil or grease on disc facings Replace disc assembly and cor-
rect cause of contamination
Clutch chatter
T
Weak or broken disc damper Replace disc assembly
springs
Broken or loose engine mount Replace or tighten mounts
AF
Excessive pedal free play Adjust clutch pedal play
Worn or damaged disc assembly Replace disc assembly
Clutch disc splines sticking Remove disc assembly and un-
Difficult gear shifting stick splines or replace disc
Clutch over stroke Adjust clutch Master Cylinder
push rod length as per spec refer
R
to pageWCH021SPROC033
Clutch pedal bushing damaged Replace parts
Worn release bearing Replace release bearing
D
Clutch noisy
Worn disc assembly Replace disc assembly
Worn diaphragm spring Replace cover assembly
Insufficient lubricant on clutch Lubricate
Clutch operation erratic or rough
pedal pivot
CLUTCH PEDAL INSPECTION AND

ADJUSTMENT
1. Turn up the floor carpet under the clutch
pedal.
2. Measure the clutch pedal height (A).
Standard value (A) :
151 mm (5.94 in)
Symbol Description
A Clutch pedal height
DOINC021R08008
B Floor carpet

CLUTCH 21
ON-VEHICLE SERVICE /5
3. If the clutch pedal height and the clutch

pedal clevis pin play are outside the standard
value, turn the setting nut in order to adjust
to the standard value.
CAUTION
Do not push in the master cylinder push rod
at this time, otherwise the clutch will not
operate properly.
4. After completing the adjustments, confirm
that the clutch pedal free play (measured at
the face of the pedal pad) and distance
between the clutch pedal ( the face of the
pedal pad) and toeboard when the clutch is
disengaged are within the standard value
ranges.
5. If the clutch pedal free play and the distance
between the clutch pedal and the toeboard
when the clutch is disengaged do not agree
with the standard values, it is probably the
T
result of either air in the hydraulic system or
a faulty master cylinder or clutch.Bleed the
air , or disassemble and inspect the master
cylinder or clutch.
AF
Symbol Description
C Free play
T1 2 mm (0.079 in) (Max)
D Distance between the clutch
pedal and teoboard when the
R
clutch is disengaged
T2 151 mm (5.94 in)
D
DOINC021R08007
BLEEDING
CLUTCH FLUID
1. Before bleeding need to remove brake fluid
first in the reservior tank as per shown in the
illustration.
• Engine running.
• Clutch fluid should always be at maxim-
um level in the reservoir tank.
• Ensure that there is no leakage around
the fluid clutch distribution.
• Install a filter to the master cylinder
DOINC35AR08013 reservoir tank when supplying clutch
fluid.
• Use the specified clutch fluid and avoid
using a mixture of the specified clutch
fluid with other fluid.

21 CLUTCH
Symbol Description
A Bottle
B Reservoir tank
2. Bleed the system when
• Clutch pipe is removed
• Clutch hose is removed
• Clutch master cylinder is removed
• Clutch pedal is spongy
Specified fluid :
Brake fluid DOT3 or DOT4
CAUTION
mixture of the specified fluid with other
fluid.
DOIMC021R08004
Symbol Description
C Clutch release cylinder
T
AF
R
D

CLUTCH 21
CLUTCH PEDAL /7
CLUTCH PEDAL WCH021SASSY11002
T
AF
R
DOINC021R08010
D
— Grease: (Multipurpose grease)

Pre-Installation operation
• Clutch Pedal Inspection and Adjustment Refer to page – (
Removal steps
1. Member assy clutch support
2. Pedal assy clutch
3. Bolt
4. Nut
T1 : 1.0 - 1.5 kgm (10 - 15 Nm, 7.23 - 10.85 ft.lbs)
T2 : 2.5 - 3.5 kgm (25 - 35 Nm, 18.08 - 25.32 ft.lbs)

21 CLUTCH
/8 CLUTCH PEDAL
T
AF
R
DOINC021R08009
Symbol:
D
Pre-Installation operation
• Clutch Pedal Inspection and Adjustment (Refer to page ).
Disassmbly steps
1. Bolt 7. Bushing
2. Clevis pin 8. Clutch pedal
3. Split pin 9. Return spring
4. Clutch pedal mounting bolt 10. Pad pedal
5. Nut 11. Pedal support member
6. Washer spring
T1 : 2.5 - 3.5 kgm (25 - 35 Nm, 18.08 - 25.32 ft.lbs)
T2 : 1.0 - 1.5 kgm (10 - 15 Nm, 7.23 - 10.85 ft.lbs)

CLUTCH 21
CLUTCH CONTROL /9
CLUTCH CONTROL WCH021SASSY11004
T
AF
R
D
DOIQC021R11004

21 CLUTCH
/ 10 CLUTCH CONTROL
Symbol:
Non-reusable parts
— Grease: (multipurpose grease unless there is a board or type specified)
• Clutch fluid draining
• Air cleaner removal
• Air cleaner installation
• Clutch fluid supplying
• Clutch pedal adjustment (Refer to page )
Clutch master cylinder removal steps
1. Pin snap
2. Pin assy
3. Clutch pedal
4. Clip retainer
5. Clutch master cylinder assy
6. Tube assy,clutch
7. Clip tube
9. Reservoir hose
10. Transmission assy
Concentric slave adapter removal steps
T
AF
4. Clip retainer
6. Tube assy clutch
8. Concentric slave adapter
Clutch tube removal steps
4. Clip retainer
7. Clip tube
6. Tube assy clutch
R
T1 : 1.0 - 1.5 kgm (10 - 15 Nm, 7.23 - 10.85 ft.lbs)

D

CLUTCH 21
CLUTCH MASTER CYLINDER / 11
CLUTCH MASTER CYLINDER WCH021SASSY11005
T
AF
R
DOIQC021R11003
D
Symbol:
— Brake fluid : DOT4
CAUTION
Do not disassemble piston assembly
Disassembly steps
1. Clip retainer
2. Spring pin
3. Nipple
4. Pin
5. Insulator
6. Push rod assembly
7. Master cylinder body
T1 : 0.9 - 1.4 kgm (9 - 14 Nm, 6.51 - 10.13 ft.lbs)

21 CLUTCH
/ 12 CLUTCH MASTER CYLINDER

WCH021SPROC11004
PUSH ROD ASSEMBLY INSTALLATION

1. Set the length of the push rod assembly to
the shown dimension in order to make the
adjustment of the clutch pedal easier.
Symbol Description
T1 95 - 103 mm (3.74 - 4.06 in)
DOIKC021R03004
T
AF
R
D

CLUTCH 21
CLUTCH COVER AND DISC / 13
CLUTCH COVER AND DISC WCH021SASSY11006
T
AF
R
DOIMT21AR11001
D
Symbol:
— Grease: (multipurpose grease unless there is a board or type specified)
Removal steps
1. Clutch Cover
2. Clutch disc
3. Concentric slave cylinder, hose assy
4. Concentric slave cylinder adapter
5. Concentric slave cylinder
T1 :1.2 kgm (12 Nm, 8.68 ft.lbs) ± 0.18 kgm (1.8 Nm, 1.3 ft.lbs)
T2 :1.5 - 2.2 kgm (15 - 22 Nm, 10.85 - 15.91 ft.lbs)

21 CLUTCH
/ 14 CLUTCH COVER AND DISC (5MTT200A)
CLUTCH COVER AND DISC

(5MTT200A) WCH021SPROC11005
CLUTCH COVER ASSEMBLY AND

CLUTCH DISC REMOVAL
1. Use the special tool to lock and secure the
clutch cover or clutch disc before remove the
bolts
Symbol Description
A Clutch disc (EZT 0045 )
B Flywheel (EZT 0044)
T
AF
DOIMT21AR11008
2. Loosen clutch cover bolts diagonally as

shown in the illustration. Back off bolts in
succession, (one or two turns) in order to
R
avoid cover flange from bending.

CAUTION
Do not clean clutch disc or release bearing
D
with cleaning solvent.
DOIMT21AR11010
SERVICE POINTS OF INSTALLATION

CLUTCH COVER ASSEMBLY AND CLUTCH
DISC INSTALLATION
1. Fit 3 holes (A) of clutch cover to 3 dowel pins
located at flywheel.
2. Pre-tighten all 6 bolts of clutch cover assy.
DOIMC021R08009

CLUTCH 21
CLUTCH COVER AND DISC (5MTT200A) / 15
3. Tighten all 6 bolts in sequence as shown in

the illustration.
10.85 - 15.91 ft.lbs)
T
AF
DOIMT21AR11011
4. Apply grease Molycoat BR2 plus or equival-

ent on the clutch disc spline approximately
0.3 g (0.011 oz, 0.003 N) before fitting tras-
R
mission by the input shaft.

5. By using the special tool (EZT 0045), position
the clutch disc to the flywheel
D
Symbol Description
A Grease molycoat BR2 plus
DOINC021R09002

21 CLUTCH
/ 16 CLUTCH COVER AND DISC (5MTT200A)
INSPECTION
CLUTCH COVER ASSEMBLY
• Check the diaphragm spring end for wear
and uneven height. Replace if wear is evident
or height difference exceeds the limit.
Limit: 0.5 mm (0.02 in)
• Check the pressure plate surface for wear
,crack and colour change.
• Check the strap plate rivets for looseness and
replace the clutch cover assembly if loosed.
DOIPC21AR10016
CLUTCH DISC
• Check the facing for loose rivets, uneven
contact, deterioration due to seizure, adhe-
sion of oil or grease and replace the clutch
disc if defective.
• Measure the rivet sink and replace the clutch
T
disc if it is out of specification.
Limit: 0.3 mm (0.012 in)
• Check for torsion spring play and damage
and if defective , replace the clutch disc.
AF
• Combine the clutch disc with the input shaft
and check sliding condition and check for
DOIMC021R08008
play in the rotating direction. If it does not
slide smoothly, check after cleaning and reas-
sembling. If the play is excessive, replace the
clutch disc and the input shaft.
R
Symbol Description
A Rivet sink
D

CLUTCH 21
CONCENTRIC SLAVE CYLINDER(CSC) / 17
CONCENTRIC SLAVE CYLINDER(CSC) WCH021SASSY11007
T
AF
R
DOIQC021R11005
D
– Non reusable parts

• Air cleaner removal (Refer to Group – 015).
• Air Cleaner Installation (Refer to Group – 015).
Removal steps
1. Retainer clip
2. Concentric slave adapter
3. Concentric sleeve cylinder
T1 : 1.2 kgm (12 Nm, 8.68 ft.lbs) ± 0.18 kgm (1.8 Nm, 1.3 ft.lbs)

21 CLUTCH
/ 18 CONCENTRIC SLAVE CYLINDER (CSC)
CONCENTRIC SLAVE CYLINDER (CSC) WCH021SPROC11006

CONCENTRIC SLAVE CYLINDER (CSC) /CONCENTRIC SLAVE ADAPTER REMOVAL
T
AF
R
D
DOIMT21AR11004
1. Carefully align concentric slave cylinder (csc) into transmission input shaft before sliding into pos-
ition
2. Ensure concentric slave cylinder (csc) seated firmly on csc seat and sleeve and align two mounting
holes to the holes on the transmission clutch housing
3. Tighten the flange bolt to the specified torque of 1.2 kgm (12 Nm, 8.68 ft.lbs) ± 0.18 kgm (1.8
Nm, 1.3 ft.lbs)
4. Align concentric slave cylinder adapter from clutch housing external hole as shown in illustra-
tion.Ensure the key on concentric slave cylinder adapter is aligned with key hole cast on transmission
clutch housing.
5. Insert concentric slave cylinder adapter into clutch housing hole until it fully enters concentric
slave cylinder (csc). Ensure the key on concentric slave cylinder adapter mates key seating surface
on clutch housing as shown in illustration.
6. Secure the fitment of concentric slave cylinder adapter in concentric slave cylinder (csc) by engaging
the snap-lock as shown in illustration
Symbol Description
1 Concentric slave cylinder adapter
2 Concentric slave cylinder (csc)

CLUTCH 21
CLUTCH / 19
Symbol Description
3 Key-hole
4 Key
5 Snap-lock
6 Key resting surface
A View – A
B View – B
T1 1.2 kgm (12 Nm, 8.68 ft.lbs) ± 0.18 kgm (1.8 Nm, 1.3 ft.lbs)
CLUTCH WCH021SPROC11007

CONCENTRIC SLAVE CYLINDER/CONCENTRIC
SLAVE CYLINDER ADAPTER INSTALLATION
1. After setting the concentric slave cylinder to
the transmission case, tighten the flange bolt
temporally.
T
AF
DOIMT21AR11002
2. Assemble the concentric slave cylinder ad-

apter with the concentric slave cylinder.
3. Tighten the flange bolt to the specified
torque of 1.2 kgm (12 Nm, 8.68 ft.lbs) ± 0.18
R
D
DOIMT21AR11003
INSPECTION
CONCENTRIC SLAVE CYLINDER ADAPTER
1. Check the O-ring for damage and deforma-
tion. If the O-ring is damaged or deformed,
replace the concentric slave cylinder adapter.
2. Check the surface that touches the concentric
slave cylinder for contamination. If contam-
inated, clean the surface with the specified
fluid.
Specified fluid: Brake Fluid DOT 4
3. Make sure there are no deformed and/or
DOIMT21AR11005 missing clips.
Symbol Description
A O-ring

21 CLUTCH
/ 20 CLUTCH
CONCENTRIC SLAVE CYLINDER,HOSE ASSY

1. Check the O-ring for damage and deforma-
tion. If the O-ring is damaged or deformed,
replace the concentric slave cylinder,hose
assy.
2. Check the surface that touches the slave cyl-
inder adapter for contamination. If contam-
inated, clean the surface with the specified
fluid.
Specified fluid: Brake Fluid DOT 4
Symbol Description
DOIMT21AR11006
B Concentric slave cylin-
der,hose assy
C O-ring
T
AF
R
D

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

TOOLS ................................................................................. 22/2

DIFFERENTIAL SEAL ................................................................ 22/3
DIFFERENTIAL SEAL LH/RH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/3
DIFFERENTIAL SEAL LH/RH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/4
TRANSMISSION OIL LEVEL CHECK ............................................... 22/5
TRANSMISSION OIL REPLACEMENT ............................................. 22/6
Transmission oil draining: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/6
Transmission oil refilling: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22/7
TRANSMISSION CONTROL .......................................................... 22/10

T
AF
TRANSMISSION ASSEMBLY ......................................................... 22/16
R
D

/2 SPECIFICATIONS
GEAR RATIO
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
Transmission oil
T
Specified lubricant
Castrol BOT130M WSD-M2C200-C
Quantity
1.8 lit (1.89 U.S.qts, 1.56
Imp.qts)
AF
TOOLS
R
To install differential oil

G922–17 Mounter
D
seal
DOIMT22DR11012
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
To supporting the engine

GENERAL SERVICE assembly during removal
Engine lifter
TOOL MZ203827 and installation transmis-
sion assembly.
DOIIC023R9007

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.
3. Remove the tie rod end connection detail
procedures refer to GROUP 37A – Steering.
4. Remove the lover arm ball joint connection
bolt refer to GROUP 33A – Lower Arm.
5. Insert a bar between transmission case and
the drive shaft in order to remove the drive
shaft.
T
AF
R
D
DOIMC022R11036

6. Use a big screw driver to pinch out the seal.

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

1. Take a new seal and put it in the transmission
housing, place the special tool G922–17on
the seal and use a hammer to knock oil seal
into the transmission housing. Hammer it all
the way in untill no further is possible.
T
AF
DOIMC022R11038
2. Locate the special tool EZT 0042 at the differ-

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

the transmission hole.
Remove the special tool EZT 0042 by pulling
slowly downward and push drive shaft com-
plete into the transmission.
NOTE
The purpose of using the special tool EZT
0042 is to prevent any damage to the oil seal
during drive shaft installation.
4. Install the lover arm ball joint connection
5. Install the tie rod end connection detail pro-
DOIMC023R11043
cedures refer to GROUP 37A – Steering.

6. Install the tyre LH/RH detail procedures refer

to GROUP 031 – Wheel and tyre.
7. Refill transmission oil (Detail procedure refer
to 22/6 ).
TRANSMISSION OIL LEVEL CHECK

WCH022SPROC11007
In case of an oil level check proceed as follow:

1. Lift up the vehicle.
T
AF
R
D
DOIMC022R11001
3. Oil level should be at the lower portion of

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

5. If level transmission oil is at the lower portion

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

WCH022SPROC11008
Transmission oil draining:
DOIMC022R11007
1. Place the car on a flat ground.
2. Start the engine and let it run to warm up
the transmission.
3. Stop the engine.
4. Lift up the vehicle and remove the lower
cover.
T
AF
DOIQC022R12001
R
D

5. Remove the drain plug and then drain the

transmission oil.
T
AF
DOIMC022R11004
6. If all transmission oil come out, install it drain

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

1. Remove the Air- cleaner (Refer Group
015–Air cleaner).
2. Disconnect speedometer connector and re-
move the speedometer.
DOIMC022R11005

3. Fill new transmission oil into the speedomet-

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

T
AF
R
D
DOIMC022R11001
5. Ensure the transmission oil come out from

reverse lamp switch hole, if transmission oil
not come out, refill transmission oil (repaid
step 2).
DOIMC022R11002

6. Install the reverse lamp switch and tighten

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

/ 10 TRANSMISSION CONTROL
TRANSMISSION CONTROL WCH022SASSY11003
T
AF
R
DOIQC022R11001
D

• Floor console removal and installation (Refer to 52A/11 ).
Selector cable and shift cable assembly removal steps
1. Selector cable connection (Transmission side)
2. Clip
3. Shift cable connection (Transmission side)
4. Shift knob
5. Clip
6. Selector cable connection (Shift lever side)
7. Shift cable connection (Shift lever side)
8. Selector cable and shift cable assembly
Shift lever assembly removal steps
4. Shift knob
5. Clip
6. Selector cable connection (Shift lever side)
7. Shift cable connection (Shift lever side)
9. Shift lever assembly
T1 : 1.0~1.5 kgm (10~15 Nm, 7.23~10.85 ft.lbs)

TRANSMISSION CONTROL / 11
NOTE
Detail procedure for removal and installation of
floor console refer to 52A/11 .
SELECTOR CABLE AND SHIFT CABLE

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

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

cable clip and remove the selector cable.
D
DOIMC022R11010

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

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

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

from the cable support.
R
D
DOIMC022R11013
7. By hand remove the selector cable clip and

disconnect the selector cable.
DOIQC022R12002

8. Use the screw driver remove the shift cable

clip and disconnection the shift cable.
DOIQC022R12003

cable from the shift lever bracket.
T
AF
DOIQC022R12004

from the shift lever bracket.
R
D
DOIQC022R12005
11. Remove the retainer nut.
DOIQC022R12006

12. Remove the selector cable and shift cable

assembly.
DOIQC022R12007
SHIFT LEVER ASSEMBLY REMOVAL

1. By hand remove the selector cable clip and
disconnect the selector cable.
T
AF
DOIQC022R12002
2. Use the small screw driver remove the shift

cable clip and disconnection the shift cable.
R
D
DOIQC022R12003

cable from the shift lever bracket.
DOIQC022R12004


from the shift lever bracket.
DOIQC022R12005
5. Remove the shift lever nuts and remove shift

lever assembly.
SELECTOR CABLE AND SHIFT CABLE
INSTALLATION
T Reverse order procedure removal to install select-

or cable and shift cable assembly.
AF
CAUTION
After install the selector cable, shift cable as-
sembly and shift lever assembly, ensure checking
DOIQC022R12008
the operation of shift lever.
SHIFT LEVER ASSEMBLY INSTALLATION

R
Reverse order procedure removal to install shift

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

the operation of shift lever.

/ 16 TRANSMISSION ASSEMBLY
TRANSMISSION ASSEMBLY WCH022SASSY11004
T
AF
R
DOIQC022R12009
D

• Air cleaner removal and installation (Refer to GROUP 015 – Air cleaner).
• Battery and battery tray removal.
• Selector cable and shift cable removal and installation (Refer to 22/11 ).
• Transmission oil draining (Refer to 22/6 ).
• Exhaust front removal and installation (Refer to GROUP 015 – Exhaust front).
• Catalytic converter removal and installation (Refer to GROUP 015 – Intake and exhaust).
• Front sub-frame removal and installation (Refer to GROUP 032 – Front sub-frame).
• Drive shaft removal and installation (Refer to GROUP 33A – Drive shaft).
• Clutch bleeding procedure (Refer to GROUP 021 – Bleeding).
NOTE:
(1) Before remove the transmission, ensure disconnect the transmission wiring harness connectors
first.
(2) Support the power steering assembly and drive shaft by wire.
(3) After install the transmission, ensure connect the transmission wiring harness connectors
properly.

TRANSMISSION ASSEMBLY / 17
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
T
AF
R
D
DOIQC022R12019
Removal steps 11. Transmission assembly lower part coupling
6. Selector cable connection bolts (5 pieces)
7. Clip 12. Starter coupling bolts (2 pieces)
8. Shift cable connection 13. Transmission assembly upper part coupling
9. Drive shaft RH bolt (3 pieces)
10. Drive shaft LH 14. Transmission mounting bracket assy
15. 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
T
AF
R
D

AIR-CLEANER REMOVAL
NOTE:
Detail service procedure for removal the Air-
cleaner, refer to GROUP 015 – Air-cleaner.
BATTERY AND BATTERY TRAY REMOVAL

NOTE:
Detail service procedure for removal the battery
and battery tray, refer to GROUP 054.
EXHAUST FRONT REMOVAL

NOTE:
Detail service procedure for removal the exhaust
front, refer to GROUP 015 – Exhaust front.
FRONT SUB FRAME REMOVAL
T NOTE:
Detail service procedure for removal the front
sub frame, refer to GROUP 032 – Front sub
AF
frame.
TRANSMISSION ASSEMBLY REMOVAL

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

connector.
DOIMC022R11042

3. Remove the speedometer harness connector.
DOIMC022R11022
4. Disconnect the Concentric slave cylinder ad-

apter hose clip (CSC).
T
AF
DOIMC022R11023
5. Lift up the vehicle, remove the lower cover.

R
D
DOIQC022R12001

6. Using the Allen key remove the drain plug

to drain the transmission oil.
T
AF
DOIMC022R11004
7. Remove the shift control front cover.

R
D
DOIMC022R11008
8. Using the plier release the selector cable and

shift cable connection from transmission se-
lector lever (Detail procedure, refer to 22/11
).
DOIMC022R11009

9. Remove the shift control back cover.
DOIMC022R11024
10. Insert a pry bar between the transmission

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

11. Hang the drive shaft with a cord for easier

to remove the transmission.
T
AF
DOIMC023R11026
12. Remove the starter lower coupling bolt.

R
D
DOIQC022R12012
13. Remove the transmission lower coupling

bolts (5 pieces).
DOIQC022R12013

14. Lift down the vehicle.

Disconnect the oxygen sensor connector.
DOIMC023R11020
15. Remove the exhaust manifold heat protector.
T
AF
DOIMC023R11021
16. Remove the catalytic converter upper

mounting nuts.
R
D
DOIMC023R11022
17. Lift up the vehicle and remove the catalytic

converter lower mounting bolts.
DOIMC023R11023

18. Remove the catalytic converter assembly.
DOIMC023R11024
19. Set the engine lifter MZ2033827 to the

vehicle in order to support the engine as-
sembly.
T
AF
DOIQC022R12014
20. Remove the starter mounting upper bolt.

R
D
DOIQC022R12015
21. Remove the transmission upper coupling

bolts (3 pieces) .
DOIQC022R12016

22. Remove the transmission mounting insulator

bolt.
DOIQC022R12017
23. Remove the transmission mounting nuts and

remove the engine mounting assy.
T
AF
DOIQC022R12018
24. Remove the transmission assembly from the

engine.
Using the garage jack, slowly lift down the
R
transmission assembly.
D
DOIQC022R12010
25. Remove the transmission from the vehicle.

CAUTION
Be careful do not drop the transmission as-
sembly.
TRANSMISSION ASSEMBLY INSTALLATION
1. Reverse order procedure removal to install
back transmission assembly.
2. Detail procedure for refilling the transmission
oil, refer to WCH022SPROC11004.
DOIQC022R12011

TRANSMISSION MOUNTING STOPPER

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

NOTE:
T Detail service procedure for install the exhaust

front, refer to GROUP 015 – Exhaust front.
AF
BATTERY AND BATTERY TRAY
INSTALLATION
NOTE:
Detail service procedure for install the battery
R
AIR-CLEANER INSTALLATION
NOTE:
Detail service procedure for install the Air-
D
cleaner, refer to GROUP 015 – Air-cleaner.

NOTE
T
AF
R
D

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

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

TOOLS ................................................................................. 23/9

CVT COMPONENT LOCATION .................................................... 23/12
VIEW LOCATION .................................................................... 23/13
SHIFT CABLE ADJUSTMENT ....................................................... 23/14
INSPECTION PROCEDURES ........................................................ 23/16
CVT FLUID REFILL / CHECK ........................................................ 23/17
CVT FLUID REPLACEMENT ........................................................
OIL LEVEL CHECK ...................................................................
DIFFERENTIAL SEAL ................................................................
T 23/21
23/23
23/26
AF
DIFFERENTIAL SEAL LH/RH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/26
DIFFERENTIAL SEAL LH/RH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/27
PRIMARY COVER .................................................................... 23/28
PRIMARY COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/28
PRIMARY COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/30
SECONDARY COVER ................................................................ 23/31
SECONDARY COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/31
R
SECONDARY COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/32

OIL PUMP ............................................................................. 23/33
OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/33
OIL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/34
D
PRIMARY BALL BEARING .......................................................... 23/35

OIL PAN AND OIL FILTER .......................................................... 23/37
DRIVE MODE SENSOR .............................................................. 23/41
HYDRAULIC UNIT ................................................................... 23/43
SECONDARY SPEED SENSOR AND BRACKET .................................. 23/45
PRIMARY SPEED SENSOR .......................................................... 23/46
MAIN CONNECTOR AND INTERNAL CABLE HARNESS ....................... 23/47
TCU AND BRACKET ................................................................... 23/51

CVT FLUID COOLER .................................................................. 23/53

TRANSMISSION CONTROL .......................................................... 23/57

SELECTOR LEVER ASSY ............................................................. 23/58

23 CVT
/2 Content
DISASSEMBLY AND REASSEMBLY (FOR CVT 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/58

DISASSEMBLY AND REASSEMBLY (FOR CVT 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/59
TRANSMISSION ASSEMBLY ........................................................ 23/64

TROUBLESHOOTING .................................................................. 23/74

STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING ..................... 23/74
TROUBLESHOOTING GUIDE ....................................................... 23/75
GENERAL REMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/75
INTERMITTENT MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/75
LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/75
NOISE PROBLEMS ................................................................... 23/76
SECONDARY GEAR SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/76
REVERSE SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/76
LOW SPEED GEAR SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/76
PRIMARY BALL BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/76
TRANSMISSION INSIDE BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/77
T
NOISE DUE TO WATER OR CONTAMINATED OIL INSIDE THE TRANSMISSION . . . . . . . . . 23/77
NOISE IN ‘N’ OR ‘P’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/78
SHOCK AND NO CREEP PROBLEMS ............................................. 23/79
SHOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/79
AF
NO CREEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/79
DIAGNOSTIC FUNCTION ........................................................... 23/80
WARNING INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/80
FREEZE FRAME DATA ............................................................... 23/80
DISPLAY ITEM LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/80
CLUTCH ADAPTATION PROCEDURE ............................................ 23/86
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/86
R
PRE-CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/86
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/86
TROUBLESHOOTING (CLUTCH ADAPTATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/91
SPECIAL FUNCTIONS ................................................................ 23/92
D
PRE-CAUTION FOR OPERATING PADT-II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/92

PRE-CONDITION CHECK OF CLUTCH ADAPTATION USING PADT-II . . . . . . . . . . . . . . . . . . . . 23/93
CVT CLUTCH ADAPTATION USING SPECIAL FUNCTION IN PADT-II . . . . . . . . . . . . . . . . . . . . . 23/94
SELF DIAGNOSIS ..................................................................... 23/100
ROAD TEST ........................................................................... 23/110
INSPECTION CHART FOR DIAGNOSIS CODE ................................... 23/112
P0710: OIL TEMPERATURE SENSOR FAULT ..................................... 23/115
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/115
TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/116
P0218: HIGH OIL TEMPERATURE ................................................. 23/118
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/118
P1767: CRITICAL OIL TEMPERATURE ............................................ 23/119
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/119
P2765: PRIMARY PULLEY SPEED SENSOR FAULT .............................. 23/121
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/121
P2766: PRIMARY PULLEY SPEED UNPLAUSIBLE ............................... 23/124
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/124
P0720: SECONDARY PULLEY SPEED SENSOR FAULT ......................... 23/127
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/127

CVT 23
Content /3

P0721: SECONDARY PULLEY SPEED UNPLAUSIBLE ........................... 23/130
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/130
P0840: SECONDARY PRESSURE SENSOR FAULT ............................... 23/133
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/133
P0641: PRESSURE SENSOR SUPPLY FAULT ...................................... 23/136
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/136
P1765: SECONDARY PULLEY PRESSURE TOO LOW ........................... 23/139
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/139
P1766: SECONDARY PULLEY PRESSURE TOO HIGH .......................... 23/141
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/141
P0651: DMS AND SPEED SENSOR SUPPLY FAULT ............................. 23/143
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/143
P0706: DRIVE MODE SENSOR SINGLE LINE ERROR ........................... 23/146
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/146
P0705: DRIVE MODE SENSOR MULTIPLE LINES ERROR ...................... 23/147
T
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P0659: HIGH SIDE SHORT CIRCUIT TO BATTERY ..............................
23/147
23/148
23/149
AF
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/149
P0658: HIGH SIDE SHORT CIRCUIT TO GROUND OR OPEN CIRCUIT ....... 23/152
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/152
P0701: DOUBLE FAULT REQUIRING HIGH SIDE OPEN ........................ 23/155
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/155
R
P0882: BATTERY OR HIGH SIDE VOLTAGE TOO LOW ........................ 23/155

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/155
P0883: BATTERY OR HIGH SIDE VOLTAGE TOO HIGH ....................... 23/160
D
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/160
P0702: WATCHDOG TEST FAILED (DURING INITIALIZATION) ............... 23/164
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/164
P0962: EDS1 (PRIMARY PULLEY) SHORT CIRCUIT TO GROUND ............ 23/165
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/165
P0963: EDS1 (PRIMARY PULLEY) SHORT CIRCUIT TO BATTERY ............ 23/168
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/168
P0960: EDS1 (PRIMARY PULLEY) OPEN CIRCUIT .............................. 23/171
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/171
P0966: EDS2 (SECONDARY PULLEY) SHORT CIRCUIT TO GROUND ........ 23/174
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/174
P0967: EDS2 (SECONDARY PULLEY) SHORT CIRCUIT TO BATTERY ........ 23/177
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/177
P0964: EDS2 (SECONDARY PULLEY) OPEN CIRCUIT .......................... 23/180
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/180

23 CVT
/4 Content
P0902: EDS3 (CLUTCH) SHORT CIRCUIT TO GROUND ........................ 23/183

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/183
P0903: EDS3 (CLUTCH) SHORT CIRCUIT TO BATTERY ........................ 23/186
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/186
P0900: EDS3 (CLUTCH) OPEN CIRCUIT .......................................... 23/189
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/189
P1761: EDS CURRENT FAULT ...................................................... 23/191
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/191
P1762: CURRENT STUCK ........................................................... 23/193
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/193
P0930: SHIFT LOCK SHORT CIRCUIT TO GROUND ............................ 23/196
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/196
P0931: SHIFT LOCK SHORT CIRCUIT TO BATTERY OR OPEN CIRCUIT ..... 23/200
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/200
P1768: BACKLIGHT SHORT CIRCUIT TO GROUND ............................ 23/204
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/204
P1769: BACKLIGHT SHORT CIRCUIT TO BATTERY OR OPEN CIRCUIT .....
T
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23/205
23/207
23/207
AF
P0868: OPERATION READINESS TIME OUT ..................................... 23/211
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/211
P0811: CLUTCH (FORWARD OR REVERSE) SLIPPING ......................... 23/211
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/211
P2787: CLUTCH TEMPERATURE TOO HIGH .................................... 23/212
R
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/212
P0730: RATIO CONTROL FAULT .................................................. 23/214
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/214
D

P1770: ENGINE SPEED TOO LOW ................................................ 23/216
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/216
P0727: HARDWIRED ENGINE SPEED UNPLAUSIBLE .......................... 23/217
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/217
P0219: POWERTRAIN SPEED OUT OF RANGE ................................. 23/219
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/219
P0944: INSUFFICIENT CLAMPING FORCE (VSM) ............................... 23/219
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/219
P1772: AT MODE SIGNAL ERROR ................................................ 23/222
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/222
P080A: EOL CLUTCH ADAPTATION NOT FINISHED ........................... 23/225
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/225
P1774: END OF LINE (EOL) CLUTCH ADAPTATION ERROR .................. 23/226
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/226
P0571: BRAKE SIGNAL ERROR .................................................... 23/228

CVT 23
Content /5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/228
U0301: VEHICLE CONFIGURATION MISMATCH ................................ 23/232
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/232
U0415: ABS FUNCTION ERROR ................................................... 23/233
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/233
U0001: CAN BUS OFF ............................................................... 23/235
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/235
U0121: CAN ABS COMMUNICATION FAILED .................................. 23/238
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/238
U0100: CAN ECU COMMUNICATION FAILED .................................. 23/239
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/239
U1012: CAN ENGINE SPEED SIGNAL ERROR ................................... 23/240
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/240
U1013: CAN ACCELERATOR PEDAL SIGNAL ERROR .......................... 23/240
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/240
U1014: CAN ENGINE TORQUE SIGNAL ERROR ................................
T
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
U1016: CAN WHEEL SPEED ERROR — FRONT LEFT ...........................
23/241
23/241
23/241
23/242
AF
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/242
U1017: CAN WHEEL SPEED ERROR — FRONT RIGHT ........................ 23/245
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/245
U1018: CAN WHEEL SPEED ERROR — REAR LEFT ............................ 23/248
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/248
R

U1019: CAN WHEEL SPEED ERROR — REAR RIGHT .......................... 23/251
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/251
D
TROUBLE SYMPTOM ................................................................. 23/253

TROUBLE SYMPTOM CHART ...................................................... 23/253
SYMPTOM PROCEDURES ............................................................ 23/255

Inspection Procedure 1: Communication with the PADT-II is not Possible 23/255
(CVT-TCU cannot be turned ON). ................................................
DIAGNOSIS PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/256
Inspection Procedure 2: Vehicle Creeps in the N Range. .................... 23/257
Inspection Procedure 3: Shock is experienced during N to D and/or N to 23/257
R shifting operation. ...............................................................
Inspection Procedure 4: Poor Acceleration or Incomplete Shifting Opera- 23/258
tion ....................................................................................
Inspection Procedure 5: Gears cannot be Changed in SAT Mode. ........ 23/260
DATA LIST ............................................................................... 23/261

DATA LIST REFERENCE TABLE ..................................................... 23/261
DATA LIST REFERENCE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/261

23 CVT
/6 Content
CHECK AT CVT TCU TERMINALS ................................................... 23/265

TERMINAL VOLTAGE ............................................................... 23/265
TERMINAL VOLTAGE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/265
CHECK AT CVT CONNECTOR ........................................................ 23/268

TERMINAL ARRANGEMENT ....................................................... 23/268
TERMINAL ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/268
DRIVE MODE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/270
T
AF
R
D

CVT 23
Content /7
NOTE
T
AF
R
D

23 CVT
OUTLINE OF CHANGES
A continuously variable transmission (CVT) is a transmission that can change steplessly through an
infinite number of effective gear ratios between maximum and minimum values. This contrasts with
automatic transmission that offers a fixed number of gear ratios. The flexibility of a CVT allows the
driving shaft to maintain a constant angular velocity over a range of output velocities.
This can provide better fuel economy than automatic transmissions by enabling the engine to run at
its most efficient revolutions per minute (RPM) for a range of vehicle speeds. Alternatively it can be
used to maximize the performance of a vehicle by allowing the engine to turn at the RPM at which
it produces peak power. This is typically higher than the RPM that achieves peak efficiency. A CVT
also does not strictly require the presence of a clutch, allowing the dismissal thereof.
Other advantages of using CVT are:
1. Low engine revolutions at constant speeds.
2. Improved emission control or fuel consumption.
3. Low noise, vibration and harshness levels.
4. Smooth acceleration.
5. Flexible driving on mountain roads.
SPECIFICATIONS
T
WCH023SPECS11005
AF
Items Specification
Transmission Model PUNCH CVT
Transmission type CVT 3
Torque converter type 3–element with torque converter clutch
Applicable engine S4PH
CVT GEAR RATIO
R
1.6 CFE
Gear
Min Max
D
CVT 3 0.46 2.55

SAT-1 2.42
SAT-2 1.28
SAT-3 0.90
SAT-4 0.70
SAT-5 0.55
SAT-6 0.46
Reverse 2.55
Final Drive 5.76
CONTINUOUS VARIABLE TRANSMISSION <CVT>
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

CVT 23
SPECIAL TOOLS /9

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
P480143
T Stamp
To install oil seal differen-
tial
AF
DOIIT23CR09010
P480142 Centering pin To install hydraulic unit

R
DOIIT23CR09009
D
P480137 Stamp To install primary bearing
DOIIT23CR09004
MD998350 Stamp To install primary bearing
DOINT23CR11032
To remove primary bear-

MD998348 Puller assembly
ing
DOINT23CR11030

23 CVT
/ 10 SPECIAL TOOLS
To remove primary bear-

MB991202 Support
ing
DOIMT22DR10152
To install drive shaft (This

tool should be used for
the prevention of differ-
EZT0042 Oil seal protector
ential side oil seal dam-
age when installing drive
shaft to transmission)
DOIMC026R07013
Mot. 1335 Circlip plier To lift out the oil pump
DOINT23CR10026
T
AF
To supporting the engine
GENERAL SERVICE assembly during removal
Engine lifter
TOOL MZ203827 and installation transmis-
sion assembly
R
DOIIC023R9007
EZT 0047
D
For vehicle diagnosis
interface (VCI)
DOIMC35BR11039

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

connector; 1 m) VCI
DOIMC35BR11041

CVT 23
SPECIAL TOOLS / 11

USB cable 1.8 m
PC and VCI
DOIMC35BR11046

DOIMC35BR11045

Ethernet cable
T
ing to VCI
DOIMC35BR11040
AF
Cable keeper
cable messy
R
DOIMC35BR11043
D
Plug adapter for power To be use with power

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

VCI Strorage case
II
DOIMC35BR11047

23 CVT
CVT COMPONENT LOCATION
T
AF
R
DOIQC023R11001
D

Backup relay BR
A
Gear shift relay GSR
CVT Transmission control unit CVT TCU B
Stop lamp switch SL Switch C
Diagnosis connector DC D
Stepped auto (SAT) button (For CVT 2) SAT button E
Shift lock override button SL override button F
Primary speed sensor (Input speed sensor) PSS G
Secondary speed sensor (Output speed sensor) SSS
Oil temperature sensor OTS
Secondary pressure sensor SPS
Drive mode sensor (Position/Inhibitor sensor) DMS H
Primary pressure regulator solenoid EDS1
Secondary pressure regulator solenoid EDS2
Clutch pressure regulator solenoid EDS3

CVT 23
VIEW LOCATION
DOIQC023R12007 DOIQC023R12004
T
AF
R
D

23 CVT
T
AF
SHIFT CABLE ADJUSTMENT WCH023SPROC11046

R
This procedure describes how to install the shift

lever inside the car correctly with the transmis-
sion.
D
If this procedure is not done according to the

instruction, it is possible that the transmission is
in the correct state of ‘P-R-N-D’ for the driver to
select.
The dashboard will always indicates what the
state of the transmission, regardless what the
position of the shift lever is.
For a good cable adjustment the dashboard and
shift lever will indicate the same position ‘P-R-N-
D’.

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

replacing new cable or servicing on the shift
lever.
DOIQC023R12008
2. Lift up the vehicle and push the shift lever

manually in ‘P’ position (ensure the shift lever
is push until end) as shown in the illustration.
T
AF
R
D
DOIQC023R11006
3. The ‘P’ position can be verified by checking

the indication on the dashboard.
DOIQC023R11007

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

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

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

Step 2 bracket cable assy
T Step 3
Step 4
• Insert washer
• Insert snap pin
AF
• Connect the cable to the shift
lever with screw and nut
DOIQC023R11008 CAUTION
Ensure the adjuster fit at the end
Step 5 of shift lever.
• Tighten the nut to the spe-
R
cified torque.
Specified torque:
1.0~1.5 kgm (10~15 Nm,
7.23~10.85 ft.lbs)
D
6. When tightening the nut, do not bend the

cable or the shift lever.
INSPECTION PROCEDURES
1. Move the selector lever to all position ‘P-R-
N-D’.
2. Ensure the selector lever inside the car is now
aligned with the transmission.
DOIQC023R12009

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

gear position is the same with the selector
lever.
CVT FLUID REFILL / CHECK WCH023SPROC11049
This procedure implies whenever the oil has

been drained from the transmission or transmis-
sion has been replaced with a new service
transmission.
Service transmissions are not pre-filled and need
to be filled up after installing in the vehicle with
DOIQC023R11009
approximately 4.15 lit (4.37 U.S.qts, 3.6 Imp.qts)
± 0.05 lit (0.053 U.S.qts, 0.043 Imp.qts) of ESSO
EZL799.
After the initial fill, the correct way to check the
oil level is listed below:
1. Insert the remote key with the buttons facing
up in the key slot until you can feel a switch
inside the key slot. This switch is to ensure
the remote key has been placed securely.
T 2. Place the shift lever in ‘P” position (park).

AF
DOIQC023R12014
R
3. Press the Start stop button once while de-

pressing the brake pedal.
Stay at idle for at least 10 seconds (note: air
D
circulating through the system may be heard

on initial start-up, this is a normal operating
condition).
DOIQC023R12012

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

D) and allow the gear to rest in each of its
position for 5 seconds before progressing to
the next position.
DOIQC023R12009
5. Move the selector lever into ‘D’ position.
T
AF
DOIQC023R12010
6. Release the foot brake.

R
D
DOIQC023R12015
7. Apply a little throttle to minimum 60 km/h

(the engine speed must not be higher than
2500 rpm).
DOIQC023R12017

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

standstill (all the noises by air circulating in
the system during the first up shifting should
be gone).
9. To increase the oil temperature, drive care-
fully around (increase the vehicle speed at
least 3 times between 0 km/h and 60 km/h),
for at least 5 minutes or until the temperat-
ure of the transmission has reached approx-
imately 60 °C (140 °F).
10. Place the car on a flat ground or ramp.
DOIQC023R12018
11. Apply the foot brake.

12. Wait two seconds.
T
AF
DOIQC023R12016
13. Move the selector lever into ‘R’ position.

14. Wait 10 seconds.
R
D
DOIQC023R12011
15. Move the selector lever into ‘P’ position.

Keep the engine running idle.
DOIQC023R12008

23 CVT
16. Lift up the vehicle, remove the lower cover

bolts flange and screws tapping.
Remove the lower cover.
DOIQC023R12019
17. Remove the oil level plug.
T
AF
DOIMC023R11061
18. Make sure minimum 0.2 lit (0.21 U.S.qts, 0.17

Imp.qts) of oil flows out of the oil level tube
after removing the level plug (otherwise the
R
initial amount of oil wasn’t sufficient).

If not, add another 0.5 litre extra and redo
complete procedure.
Wait a few minutes until the oil that comes
D
out of the level begins to drip.
DOIMC023R11062
19. Refit the oil level plug with sealing ring.

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

CVT 23
20. Install the lower cover.

Tighten the bolts flange and screws tapping
Specified torque:
Bolts flange 0.77 kgm (7.7 Nm, 5.57
ft.lbs)
Screws tapping 0.31 kgm (3.1 Nm, 2.24
ft.lbs)
DOIQC023R12019
21. Lift down the vehicle and stop the engine

while pressing the start stop button.
T
AF
DOIQC023R12013
CVT FLUID REPLACEMENT WCH023SPROC11050

R

D
DOIQC023R12019

23 CVT
2. Remove the drain plug and drain the trans-

mission oil.
Install back the drain plug and torque to the
specified torque.
Specified torque:
0.72 ft.lbs).
T
AF
DOIMC023R11120
3. Remove the oil filling plug on top of the

transmission.
R
D
DOIQC023R11022
4. Fill the transmission oil with exactly 4.15 lit

(4.37 U.S.qts, 3.6 Imp.qts) ± 0.05 lit (0.053
U.S.qts, 0.043 Imp.qts) .
Transmission oil:
ESSO EZL799
DOIQC023R11023

CVT 23
5. Refit the oil filling plug together with the

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

oil, refer to 23/17 .
OIL LEVEL CHECK WCH023SPROC11051
If the initial fill was done properly, the oil level

will be at a correct level (“level-plug” level).
DOIQC023R11022
Due to tolerances (such as: new transmissions are
delivered with a residual oil volume and initial
fill tolerances) the tolerance on the correct
“level-plug”-level will be ± 0.165 lit (0.17 U.S.qts,
0.14 Imp.qts).
In case of an oil level check proceed as follow:
transmission.
T
AF
R
DOIQC023R11022
2. Fill the transmission with exactly 0.5 lit (0.53

U.S.qts, 0.43 Imp.qts) ± 0.05 lit (0.053 U.S.qts,
D
0.043 Imp.qts).
DOIQC023R11023

23 CVT

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

fully around for at least 5 minutes or until
the temperature of the transmission has
reached approximately 60 °C (140 °F).
5. Place the car on a flat ground.
DOIQC023R11022
6. Apply the foot brake.

7. Wait two seconds.
T
AF
DOIQC023R12016
8. Move the selector lever into ‘P’ position.

9. Keep the engine running idle.
R
D
DOIQC023R12008

DOIQC023R12019

CVT 23
11. Remove the oil level plug (while engine

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

U.S.qts, 0.29 Imp.qts) and max 0.665 lit (0.7
U.S.qts, 0.58 Imp.qts))
12.1 Minimum 0.335 lit (0.35 U.S.qts, 0.29
Imp.qts) ( 0.5 ADDED OIL - 0.165 toler-
ances = 0.335 Litre ) oil will drain out
off the transmission.
T If the collected amount is less: the initial

level was too low
12.2 Maximum 0.665 lit (0.7 U.S.qts, 0.58
AF
Imp.qts) ( 0.5 ADDED OIL + 0.165 tol-
erances = 0.665 Litre ) oil will drain out
DOIMC023R11062 off the transmission.
If the collected amount is more: the
initial level was too high
* The mentioned values are valid for
R
exactly 60 deg.
13. Refit the oil level plug with sealing ring.
Specified torque:
1.8~2.4 kgm (18~24 Nm, 13.02~17.36 ft.lbs)
D
DOIMC023R11061

23 CVT

Specified torque:
ft.lbs)
ft.lbs)
DOIQC023R12019
15. Lift down the vehicle and stop the engine

while pressing the start stop button.
DIFFERENTIAL SEAL WCH023SPROC11052
In case of damage/leakage on seal or half shaft.

DIFFERENTIAL SEAL LH/RH REMOVAL
T 1. Drain transmission oil (Detail procedure refer

to 23/17 ).
AF
2. Remove the tyre LH/RH detail procedures
refer to GROUP 031 – Wheel and tyre.
3. Remove the tie rod end connection detail
DOIQC023R12013
procedures refer to GROUP 37A – Steering.
4. Remove the lover arm ball joint connection
R
D

CVT 23
5. Insert a bar between transmission case and

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

Be careful not to put screwdriver in too deep,
otherwise the housing can be damaged by
R
the tip of the screwdriver.

D
DOIMC023R11040
DIFFERENTIAL SEAL LH/RH INSTALLATION

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

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

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

the transmission hole.
Remove the special tool EZT 0042 by pulling
slowly downward and push drive shaft com-
plete into the transmission.
NOTE
T
The purpose of using the special tool EZT
0042 is to prevent any damage to the oil seal
during drive shaft installation.
AF
4. Install the lover arm ball joint connection
5. Install the tie rod end connection detail pro-
DOIMC023R11043
cedures refer to GROUP 37A – Steering.
6. Install the tyre LH/RH detail procedures refer
to GROUP 031 – Wheel and tyre .
7. Refill transmission oil (Detail procedure refer
R
to 23/17 ).
PRIMARY COVER WCH023SPROC11053

D
In case of leakage on primary cover.

PRIMARY COVER REMOVAL
DOIQC023R12019

CVT 23

mission oil approx 1 litre.
specified torque.
Specified torque:
0.72 ft.lbs).
T
AF
DOIMC023R11120
3. Remove the primary cover bolts and clips.

R
D
DOIMC023R11045
4. Use a screw driver to lift out the primary

cover. Use some cloth to protect the transmis-
sion case from damage.
DOIMC023R11046

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

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

first.
AF
DOIMC023R11048
2. Install the primary cover to the transmission

housing.
By hand knock the primary cover.
R
NOTE
In case of damaged cover, take a new
primary cover.
D
DOIMC023R11049
3. Fix the clips and tighten the bolts to the

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

CVT 23

transmission.
DOIQC023R11022
5. Refill transmission oil approx 1 litre as shown

T
AF
DOIQC023R11023

sealing ring.
Specified torque:
R
1.8~2.4 kgm (18~24 Nm, 13.02~17.36 ft.lbs).
SECONDARY COVER
D
WCH023SPROC11054
In case of secondary cover damage or leakage.
DOIQC023R11022
SECONDARY COVER REMOVAL

1. Remove the secondary cover screws.
DOIMC023R11051

23 CVT
2. Remove the secondary cover.
DOIMC023R11052
3. Use the small screw driver to remove the O-

rings and center sealing ring.
T
AF
DOIMC023R11053
SECONDARY COVER INSTALLATION

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

NOTE
In case of damaged cover, take a new second-
ary cover.
DOIMC023R11052

CVT 23
3. Tighten the secondary cover screws to the

specified torque.
Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.09 kgm (0.9
Nm, 0.65 ft.lbs).
OIL PUMP WCH023SPROC11055
In case the transmission pressure is too low or

the driver feel shocks or abnormal driving beha-
viour, two main parts can cause this problem,
DOIMC023R11051
hydraulic unit or oil pump.
Also analyze the P-code and follow actions on
specific P-code to replace either hydraulic unit
or pump.
In most of cases it is unclear which one the
problem causes so one by one can be replaced
and see if the problem is solved.
OIL PUMP REMOVAL
T 1. Remove the primary cover (Detail procedure

for removal and installation of primary cover
refer to 23/28 ).
AF
2. Remove the oil pump bolts.
R
D
DOIMC023R11080
3. Use the special tool Mot. 1335 to lift out the

oil pump.
DOIMC023R11081

23 CVT
4. By hand remove the oil pump.

CAUTION
Be careful, do not drop oil pump.
DOIMC023R11082
5. Remove the belle-ville washer.
T
AF
DOIMC023R11083
OIL PUMP INSTALLATION

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

properly.
CAUTION
Ensure the oil pump O-rings not protrude.
DOIMC023R11082

CVT 23
3. Tighten the oil pump bolts to the specified

torque.
Specified torque:
0.72 ft.lbs).
CAUTION
Torque the bolts as sequence as shown in
the illustration.
4. Install the primary cover (Detail procedure
refer to 23/28 ).
DOIMC023R11084
PRIMARY BALL BEARING WCH023SPROC11056
In case of worn out primary ball bearing.

A worn out primary ball bearing gives a big noise
for which the frequency is dependent on engine
speed.
This can be easily checked by driving at a con-
T
stant speed and shift to sport mode.
The engine rpm will go up and if the noise fre-
quency also goes up, then there is a big possibil-
AF
ity that you have a worn out primary ball bear-
ing.
PRIMARY BALL BEARING REMOVAL
1. Remove the primary cover (Detail procedure
refer to 23/28 ).
R
2. Remove the oil pump (Detail procedure for

removal and installation of oil pump refer
to 23/33 ).
3. To remove the primary nut, ensure to do a
D
marking on it permanently.
DOIMC023R11085

23 CVT
4. Use socket with the size of 46 mm (1.81 in)

by using high spec of an air impact wrench
due to remove the primary nut.
DOIMC023R11086
5. Lever out the seal of the primary ball bearing

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

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

1. By hand fix the ball bearing to the ball
bearing housing.
DOIMC023R11089

CVT 23
2. Use the special tools P480137 and MD998350

to install the primary ball bearing.
DOIMC023R11090
3. By hand fix the primary nut.
T
AF
DOIMC023R11091
4. Using air impact tighten primary nut to the

specified torque.
Specified torque:
R
19.75 kgm (197.5 Nm, 142.85 ft.lbs) ± 1.75

kgm (17.5 Nm, 12.66 ft.lbs).
CAUTION
D
Ensure the marking is at it original position.

5. Install the oil pump (Detail procedure for
removal and installation of oil pump refer
to 23/33 ).
6. Install the primary cover (Detail procedure
DOIMC023R11086 for removal and installation of primary cover
refer to 23/28 ).
OIL PAN AND OIL FILTER WCH023SPROC11057
In case of oil pan damage and or leak.

23 CVT
OIL PAN AND OIL FILTER REMOVAL

DOIQC023R12019

mission oil.
specified torque.
Specified torque:
0.72 ft.lbs).
T
AF
R
D
DOIMC023R11120
3. Remove the oil pan bolts.
DOIMC023R11092

CVT 23
4. Remove the oil pan and gasket.

CAUTION
(1) Even though the transmission oil has
been drained out, there will be some oil
remaining in the oil pan.
(2) Be careful not to splash the transmission
oil.
DOIMC023R11093
5. Remove the oil filter by pulling it gently.
T
AF
DOIMC023R11094
OIL PAN AND OIL FILTER INSTALLATION

1. Before install the oil filter, lubricate the O-
ring with clean ESSO EZL799.
R
D
DOIMC023R11095
2. Clean the magnet and surface of oil pan.
DOIMC023R11096

23 CVT
3. Install oil pan, gasket and filter together to

the transmission (center hole of oil filter
should match center bolt of hydraulic unit).
DOIMC023R11097
4. Tighten oil pan bolt to the specified torque.

Specified torque:
0.72 ft.lbs).
CAUTION
T the illustration.
AF
R
D
DOIMC023R11098

Specified torque:
ft.lbs)
ft.lbs)
6. Fill transmission oil according instruction,

(Detail procedure for fill and check transmis-
sion oil refer to 23/17 ).
DOIQC023R12019

CVT 23
DRIVE MODE SENSOR WCH023SPROC11058
In case of faulty drive mode sensor.

Dedicated error code should indicate problem
with drive mode sensor.
Replace drive mode sensor when error code ac-
tion indicates it.
DRIVE MODE SENSOR REMOVAL
1. Remove the oil pan and oil filter, (Detail
procedure for remove the oil pan and oil fil-
ter refer to 23/37 ).
2. Push the shift lever manually is in ‘P’ position.
T
AF
DOIMC023R11101
3. Remove the 2 bolts of the drive mode sensor.

R
D
DOIMC023R11102
4. Push the sensor down to remove the pin

from the metal slide.
DOIMC023R11103

23 CVT
5. Use small screwdriver to unlock the gray lock

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

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

slide, with the guiding pin on the back of
the sensor locked in the metal slide groove.
R
D
DOIMC023R11103
3. Align the drive mode sensor so the screw

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

cedure for install the oil pan and oil filter
refer to 23/37 ).
DOIMC023R11102

CVT 23
HYDRAULIC UNIT WCH023SPROC11059
In case there is a problem with the transmission

pressure or the driver feel shocks or abnormal
driving behavior, two main parts can cause this
problem, hydraulic unit or oil pump.
Also analyze the P-code and follow actions on
specific P-code to replace either hydraulic unit
or pump.
In most of cases it is unclear which one the
problem causes so one by one can be replaced
and see if the problem is solved.
HYDRAULIC UNIT REMOVAL
2. Remove the drive mode sensor, (Detail pro-
cedure for remove the drive mode sensor
refer to 23/41 ).
3. Remove the 20 pieces bolt of the hydraulic
T unit.
AF
R
DOIMC023R11106
4. Take out the hydraulic unit and disconnect

D
the 4 connectors.
DOIMC023R11107

23 CVT
HYDRAULIC UNIT INSTALLATION

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

CAUTION
Make sure that the hydraulic unit metal slide
fits in the pin of the rooster cam plate.
T
AF
R
D
DOIMC023R11108
3. Place the center screw and hand tighten it

and fix the special tool P480142 on the top
left screw hole and screw it in.
DOIMC023R11109

CVT 23
4. Place all screws of hydraulic unit, except the

upper left one, remove the special tool
P480142, and tighten upper left bolt.
Tighten the bolt to the specified torque.
Specified torque:
0.72 ft.lbs).
CAUTION
the illustration.
5. Install the drive mode sensor, (Detail proced-
ure for remove the drive mode sensor refer
to 23/41 ).
refer to 23/37 ).
SECONDARY SPEED SENSOR AND

BRACKET
T
WCH023SPROC11060
In case indicate by actions from the error code

list.
AF
SECONDARY SPEED SENSOR AND BRACKET
REMOVAL
DOIMC023R11110 1. Remove the oil pan and oil filter, (Detail
R

refer to 23/41 ).
3. Remove the hydraulic unit, (Detail procedure
for remove the hydraulic unit refer to 23/43
D
).
4. Remove the bolt of the bracket secondary
speed sensor.
DOIMC023R11156

23 CVT
5. Using plier remove the secondary speed

sensor.
DOIMC023R11157
SECONDARY SPEED SENSOR AND BRACKET

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

bolt to the specified torque.
Specified torque:
R
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.095 kgm

(0.95 Nm, 0.69 ft.lbs).
3. Install the hydraulic unit, (Detail procedure

D
for install the hydraulic unit refer to 23/43 ).

ure for remove the drive mode sensor refer
to 23/41 ).
DOIMC023R11156 cedure for install the oil pan and oil filter
refer to 23/37 ).
PRIMARY SPEED SENSOR WCH023SPROC11061

list.
PRIMARY SPEED SENSOR REMOVAL
1. Remove the primary cover, (Detail procedure
for remove the primary cover refer to 23/28
).

CVT 23
2. Using plier remove the primary speed sensor

connector.
DOIMC023R11112
3. Remove the bolt and take out the primary

speed sensor.
T
AF
DOIMC023R11113
PRIMARY SPEED SENSOR INSTALLATION

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

3. Install the primary cover, (Detail procedure
for install the primary cover refer to 23/28 ).
MAIN CONNECTOR AND INTERNAL CABLE

HARNESS WCH023SPROC11062

list.
DOIMC023R11114

23 CVT

HARNESS REMOVAL
refer to 23/41 ).
3. Remove the hydraulic unit, (Detail procedure
for remove the hydraulic unit refer to 23/43
).
4. Disconnect the secondary speed sensor, (De-
tail procedure for disconnect the secondary
speed sensor refer to 23/45 ).
5. Remove the primary cover, (Detail procedure
for remove the primary cover refer to 23/28
).
6. Disconnect the primary speed sensor connect-
or, (Detail procedure for disconnect the
primary speed sensor refer to 23/46 ).
T 7. Disconnect the car cable harness connector

from the main connector and internal cable
harness on the transmission.
AF
8. Using plier remove the main connector clip.
R
D
DOIMC023R11115
9. Press the main connector and internal cable

harness with finger into the transmission.
DOIMC023R11116

CVT 23
10. Remove the main connector and internal

cable harness.
DOIMC023R11117

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

harness properly.
CAUTION
R
Ensure the connect slot lock at transmission

case.
D
DOIMC023R11118

23 CVT
3. Install the clip main connector properly.

4. Reconnect the primary speed sensor connect-
or, (Detail procedure for reconnect the
primary speed sensor refer to 23/46 ).
5. Reconnect the secondary speed sensor, (De-
tail procedure for reconnect the secondary
speed sensor refer to 23/45 ).
6. Install the primary cover, (Detail procedure
for install the primary cover refer to 23/28 ).
7. Install the hydraulic unit, (Detail procedure
for install the hydraulic unit refer to 23/43 ).
DOIMC023R11119 ure for remove the drive mode sensor refer
to 23/41 ).
refer to 23/37 ).
T
AF
R
D

CVT 23
TCU AND BRACKET / 51
TCU AND BRACKET WCH023SASSY11009
T
AF
R
DOIQC023R11024
D

CAUTION
(1) Before remove the TCU wiring harness connectors, ensure disconnect the battery terminal first.
(2) After install the TCU, ensure connect the TCU wiring harness connectors fits in firmly on TCU
pin-out cavity and secure the connector locking mechanism.
TCU removal steps:
1. TCU wiring harness connector.
2. CVT TCU assembly
TCU bracket removal steps:
1. TCU wiring harness connector.
2. CVT TCU assembly
3. TCU bracket
T1 : 0.51 kgm (5.1 Nm, 3.69 ft.lbs) ± 0.10 kgm (1 Nm, 0.72 ft.lbs)

23 CVT
/ 52 TCU AND BRACKET
TCU REMOVAL
CAUTION
Before remove the TCU wiring harness connect-
or, ensure disconnect the battery terminal first.
1. Push out the lock lever TCU connector.
DOIQC023R12020
T 2. Disconnect the TCU connector.

AF
R
DOIQC023R12021
D
3. Pull out the TCU from the bracket slot.

TCU INSTALLATION
Reverse order procedure removal to install the
TCU.
CAUTION
After install the TCU , ensure the connector fits
in firmly on TCU pin-out cavity and secure the
connector locking mechanism.
DOIQC023R12022

CVT 23
CVT FLUID COOLER / 53
CVT FLUID COOLER WCH023SASSY11010
T
AF
R
DOIQC023R11028
D

• Front bumper removal and installation (Refer to 51/5 .)
• Lower air guide removal and installation (Refer to 42/57 .)
• CVT fluid refilling (Refer to 23/17 .)
CVT fluid cooler removal steps
1. CVT fluid cooler hose assembly
2. CVT fluid cooler assembly
T1 : 0.39~0.54 kgm (3.9~5.4 Nm, 2.82~3.91 ft.lbs)

23 CVT
/ 54 CVT FLUID COOLER
NOTE
(1) Detail for removal and installation procedure
of front bumper refer to 51/5 .
(2) Detail procedure for CVT fluid refill and
check refer to 23/17 .
CVT FLUID COOLER ASSY REMOVAL

1. Remove the front bumper.
Detail for removal and installation procedure
of front bumper refer to 51/5 .
DOIQC023R12023
T 2. Lift up the vehicle, remove the lower cover

AF
R
DOIQC023R12019
D
3. Remove the lower air guide clips and remove

the lower air guide.
DOIQC023R12025

CVT 23
CVT FLUID COOLER / 55
4. Press and release the CVT fluid cooler hose

connections (Transmission side).
DOIQC023R12024
5. Remove the CVT fluid cooler hose bracket

bolt.
T
AF
DOIQC023R12026
6. Press and release the CVT fluid cooler hose

connections (CVT fluid cooler side).
R
D
DOIQC023R12027
7. Remove the CVT fluid cooler upper bolts.
DOIQC023R12028

23 CVT
/ 56 CVT FLUID COOLER
8. Remove the CVT fluid cooler lower bolts and

remove the CVT fluid cooler assy.
CAUTION
Be careful, do not drop the CVT fluid cooler
assy.
DOIQC023R12029

CVT FLUID COOLER ASSY INSTALLATION
1. Reverse order the removal procedure to in-
stall back CVT fluid cooler assy.
CAUTION
T (1) Ensure CVT fluid cooler hose install at

right position.
(2) Ensure CVT fluid cooler hose fit firmly
AF
when installed.
(3) Ensure to inspect the CVT fluid volume
DOIQC023R11023 is at the specified level.
2. Detail procedure for refilling the CVT fluid
and level check, refer to 23/17 .
R
D

CVT 23
TRANSMISSION CONTROL WCH023SASSY11011
T
AF
R
DOIQC023R11036
D

• Floor console removal and installation (Refer to 52A/11 .)
CAUTION:
(1) Be careful not to subject the SRS-ECU to any shocks during removal and installation of the
transmission control cable and selector lever assembly.
(2) Turn “ON” ignition switch and apply brake pedal before move the selector lever.
(3) After install the Cable assy CVT and selector lever assy, ensure checking the operation of selector
lever.

23 CVT
Cable assy CVT removal steps

1. Cable assy CVT connection (Side lever selector).
2. Nut
3. Snap pin (Transmission side).
4. Washer
5. Cable assy CVT connection (Transmission side).
6. Nut
7. Adjuster
8. Cable assembly CVT
Selector lever assy removal steps
1. Cable assembly CVT connection (Side lever selector).
9. Selector lever assy.
T1 : 1.0~1.5 kgm (10~15 Nm, 7.23~10.85 ft.lbs)
SELECTOR LEVER ASSY
DISASSEMBLY AND REASSEMBLY (FOR CVT 2)
T
AF
R
D
DOIQC023R12035
Component list:

CVT 23
1. Lever sub-assy CVT2 7. Shift lock solenoid

2. Mounting damper 8. Wire harness assy CVT2
3. Collar 9. Panel assy indicator CVT2 (RHD)
4. Lever sub 10. Panel assy indicator CVT2 (LHD)
5. Shift lock assy 11. Shift knob CVT
6. Shift lock lever
DISASSEMBLY AND REASSEMBLY (FOR CVT 3)
T
AF
R
D
DOIQC023R12037
Component list:
1. Lever sub-assy CVT3 8. Wire harness assy CVT3
2. Mounting damper 9. Bulb
3. Collar 10. Gear shift control unit
4. Lever sub 11. Gear shift lock assy
5. Shift lock assy 12. Panel assy indicator CVT3
6. Shift lock lever 13. Shift knob CVT
7. Shift lock solenoid

23 CVT
CAUTION
(1) Be careful not to subject the SRS-ECU to any
shocks during removal and installation of
the cable assy CVT.
(2) Turn “ON” ignition switch and apply brake
pedal before move the gear lever.
CABLE ASSY CVT REMOVAL

1. Remove the floor console, detail procedure
refer to 52A/11 .
2. Push out the cable assembly CVT connection
from the selector lever assy.
T
DOIQC023R12030
3. Use the plier to release the cable assy CVT

lock from selector lever assy.
AF
R
D
DOIQC023R12031
4. Lift up the vehicle, release the cable assy CVT

from the cable support.
DOIMC023R11003

CVT 23
5. Remove the retainer nuts as shown in the il-

lustration.
DOIMC023R11005

lock.
T
AF
DOIMC023R11006
7. Use the plier to remove the snap pin and

washer from the transmission lever selector
shaft.
R
D
DOIMC023R11007
8. Push out the cable assy CVT connection from

the transmission lever selector shaft.
DOIMC023R11008

23 CVT
9. Pull out the cable assy CVT from the floor

hole.
DOIMC023R11009
SELECTOR LEVER ASSY REMOVAL

1. Push out the cable assembly CVT connection
from the selector lever assy.
T
AF
DOIQC023R12030

lock from selector lever assembly.
R
D
DOIQC023R12031
3. Remove the selector lever nuts.
DOIQC023R12032

CVT 23
4. Disconnect the connector harness selector

lever.
DOIQC023R12033
5. Remove the selector lever assy.
T
AF
DOIQC023R12034

CAUTION
R
After install the cable assy CVT and selector lever

assembly, ensure to check the operation of se-
lector lever.
D
CABLE ASSY CVT INSTALLATION

Reverse order the removal procedure to install
cable assy CVT.
SELECTOR LEVER ASSY INSTALLATION

DOIQC023R12009
selector lever assy.

23 CVT
TRANSMISSION ASSEMBLY WCH023SASSY11012
T
AF
R
DOIQC023R11042
D

• Air cleaner removal and installation (Refer to GROUP 015 - Air cleaner).
• Charge air duct removal and installation (Refer to GROUP 015 - Intercooler).
• Battery and battery tray removal.
• Transmission oil draining (Refer to 23/21 ).
• Exhaust front removal and installation (Refer to GROUP 015 - Exhaust front).
• Catalytic converter removal and installation (Refer to GROUP 015 - Intake and exhaust).
• Front sub-frame removal and installation (Refer to GROUP 032 - Front sub-frame).
• Drive shaft removal and installation (Refer to 23/26 ).
• Shift cable adjustment (Refer to 23/14 ).
NOTE:
(1) Before remove the transmission, ensure disconnect the engine wiring harness connectors first.
(2) After install the transmission, ensure connect the engine wiring harness connectors properly.
(3) After install the transmission, ensure to check the operation of the shift lever.
(4) After install the transmission, ensure to check the operation of the meter and gauge.
(5) Support the power steering assembly and drive shaft by wire.
Removal steps:
1. Battery terminal (+/-).
2. CVT main harness connector.
3. CVT fluid cooler hose connection.

CVT 23
T
AF
DOIQC023R11043
R
Non-reusable parts
Removal steps 11. Transmission assembly lower part coupling
4. Snap pin
D
bolts (5 pieces)
5. Washer 12. Starter coupling bolts (2 pieces)
6. Cable assy CVT connection 13. Pump recirculation assy
7. Nut 14. Transmission assembly upper part coupling
8. Adjuster bolt (3 pieces)
9. Drive shaft RH 15. Transmission mounting bracket assy
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 : 1.0~1.5 kgm (10~15 Nm, 7.23~10.85 ft.lbs) 2.17 ft.lbs)
T3 : 4.8~5.2 kgm (48~52 Nm, 34.72~37.61 ft.lbs) T7 : 5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.5 kgm (5 Nm,
T4 : 3.5~4.5 kgm (35~45 Nm, 25.32~32.55 ft.lbs) 3.62 ft.lbs)
T8 : 2.2~2.6 kgm (22~26 Nm, 15.91~18.81 ft.lbs)
CAUTION:
Mounting locations marked by * should be provisionally tightened and then fully tightened when

23 CVT
AIR-CLEANER REMOVAL
NOTE:
Detail service procedure for removal the Air-
cleaner, refer to GROUP 015 - Air cleaner.
BATTERY AND BATTERY TRAY REMOVAL

NOTE:
Detail service procedure for removal the battery
CHARGE AIR DUCT ASSY REMOVAL

NOTE:
Detail service procedure for removal the charge
air duct assy, refer to GROUP 015 - Intercooler.
CVT CABLE ASSY REMOVAL
T NOTE:
Detail service procedure for removal the CVT
cable assy, refer to 23/60 .
AF
NOTE:
Detail service procedure for removal the front
sub frame, refer to GROUP 032 – Front sub
frame.
R
TRANSMISSION ASSEMBLY REMOVAL

1. Remove the air cleaner bracket.
D
DOIQC023R12038

CVT 23
2. Remove the all CVT harness brackets at the

transmission.
DOIQC023R12039
3. Remove the CVT main connector.
T
AF
DOIQC023R12040
4. Disconnect the oxygen sensor connector

harness.
R
D
DOIQC023R12041
5. Remove the heat shield turbo lower.
DOIQC023R12042

23 CVT
6. Remove the heat shield turbo upper.
DOIQC023R12043
7. Remove the catalytic converter upper nuts.
T
AF
DOIQC023R12044
8. Remove the tank assy condenser.

R
D
DOIQC023R12045
9. Remove the fan motor shroud and bracket

assy.
DOIQC023R12047

CVT 23
10. Remove the catalytic converter bracket bolts.
DOIQC023R12048
11. Remove the catalytic converter assy.
T
AF
DOIQC023R12049
12. Lift up the vehicle, using the Allen key re-

move the drain plug to drain the transmis-
sion oil.
R
D
DOIQC023R12050

the drive shaft LH.
NOTE
Hang the drive shaft with a wire cord for
easier to remove the transmission.
CAUTION
sion case.
DOIQC023R12051 seal.

23 CVT

the drive shaft RH.
NOTE
Hang the drive shaft with a wire cord for
easier to remove the transmission.
CAUTION
sion case.
DOIQC023R12051 seal.
15. Remove the transmission lower coupling
bolts (5 pieces).
T
AF
DOIQC023R12053
16. Remove the starter lower mounting bolt.

R
D
DOIQC023R12054
17. Remove the pump recirculation assy bolt.
DOIQC023R12055

CVT 23
18. Disconnect the CVT fluid cooler hose connec-

tion.
DOIQC023R12056
19. Lift down the vehicle, set the garage jack to

the vehicle in order to support the engine
and transmission assembly.
T
AF
DOIQC023R12057
20. Remove the earth upper starter mounting

bolt.
R
D
DOIQC023R12058
21. Remove the transmission upper coupling

bolts.
DOIQC023R12059

23 CVT
22. Remove the transmission mounting bracket

assy.
DOIQC023R12060
23. Using the screw driver pry out the transmis-

sion.
T
AF
DOIQC023R12061
24. Slowly lift down the transmission assy and

remove the transmission from the vehicle.
CAUTION
R
Be careful do not damage the transmission case.

D
TRANSMISSION ASSEMBLY INSTALLATION

back transmission assembly.
2. Detail procedure for refilling the CVT fluid,
refer to 23/17 .
DOIQC023R12062

INSTALLATION
Install the transmission mounting stopper by
ensuring the arrow is 'UP' direction as shown in
the illustration.
CAUTION:
Please ensure the transmission mounting stopper
is properly fitted and installed at it position be-
fore tightening the transmission insulator
mounting bolt.
DOIMC023R11035

CVT 23
FRONT SUB FRAME INSTALLATION

NOTE:
Detail service procedure for install the front sub
frame, refer to GROUP 032 – Front sub frame.
CVT CABLE ASSY INSTALLATION

NOTE:
Detail service procedure for install the CVT cable
assy, refer to 23/60 .
BATTERY AND BATTERY TRAY

INSTALLATION
NOTE:
Detail service procedure for install the battery
AIR-CLEANER INSTALLATION
NOTE:
T Detail service procedure for install the Air-

cleaner, refer to GROUP 015 - Air cleaner.
AF
CHARGE AIR DUCT ASSY INSTALLATION
NOTE:
Detail service procedure for install the charge
air duct assy, refer to GROUP 015 - Intercooler.
R
D

23 CVT
STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
T
AF
R
D
DOINC023R11061

CVT 23
TROUBLESHOOTING GUIDE WCH023TSHOT11167
GENERAL REMARKS
Whenever there is an error detected by the transmission control unit (CVT-TCU), CVT warning 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.
T DOIQC023R11044
AF
Symbol Description
A CVT warning lamp
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:
R
1. Check oil type.

2. Check oil level.
3. Redo clutch adaptation.
D
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

23 CVT
No Fault Action
5 Leak from selector shaft lever Replace selector shaft lever seal
6 Leak from input shaft Replace input shaft seal
7 Leak from differential oil seal(s) Replace differential oil seals
1. Ensure pipes are correctly tightened
Leak from oil cooler pipe connec-
8 2. Replace pipes to oil cooler connection sealing rings
tions
3. Replace pipes
NOISE PROBLEMS WCH023TSHOT11168
SECONDARY GEAR SOUND

Sound description:
Sound best heard with a vehicle speed between 60 km/h (37.28 mph) to 90 km/h (55.92 mph) while
slowly accelerating. When releasing the gas pedal, sound normally is getting slower, give throttle
again, the sound comes back. The sound is like a whistle sound. The frequency of the sound goes up
with the vehicle speed. This is a normal sound from transmission which comes from the secondary
gear running into the pinion shaft gear.
REVERSE SOUND
Sound description:
T
When standing still and shift to ‘R’, a small whistle sound can be heard. When releasing brake and
start driving in ‘R’, the sound gets bigger and turns into a whining sound. This is a normal sound from
AF
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 heard. 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.
R
PRIMARY BALL BEARING NOISE

Sound description:
During driving in ‘D’ at low speed, the car makes a noise like “wengweng” noise. The frequency and
D
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 23/35 .
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 23/35 .

CVT 23
TRANSMISSION INSIDE BEARING NOISE

Sound description:
During driving in ‘D’ at low speed, the car makes a noise like a “wengweng” noise.
1. According to the primary ball bearing noise, if the frequency and volume of the noise does not
relate with engine speed but relate to vehicle speed, then the noise could come from transmission
inside the bearings.
2. This cannot be repaired and complete transmission needs to be replace.
NOTE
Noise problems are very hard to evaluate. So before decide to replace a part of transmission or change
the complete transmission, be sure that the noise is actually coming from the transmission. Check or
replace other parts of the car which are easier to replace first.
Use the following chart to locate the origin of the noise:
T
AF
R
D
DOINC023R11062
NOISE DUE TO WATER OR CONTAMINATED OIL INSIDE THE TRANSMISSION

Sound description:
1. Brake the car and shift to ‘D’ or ‘R’.
2. After you release the brake, a ‘gegege’ sound can be heard. This can be heard as soon as the car
is moving.
3. While giving a throttle to accelerate (from creeping speed about 10 km/h (6.21 mph)), a ‘zhi~’
sound can be hear between speed 10 km/h (6.21 mph) to 40 km/h (24.85 mph).

23 CVT
NOTE
In the early stage of water contamination, it is possible you only hear the ‘gegege’ sound and not
the ‘zhi~’ sound. Some cars can also have a shock when taking off, depends on the level of con-
tamination.
1. Drain transmission oil (Refer to page 23/17 ) and remove oil pan (Refer to page 23/37 ) as well as
the primary cover (Refer to page 23/28 ).
2. If inside the primary cover and oil pan shows white stuff, then it is clear that the transmission has
been contaminated with water or other liquid.
3. Drain the transmission oil as much as possible and discard the oil filter (Refer to page 23/37 ).
4. Place new oil filter and refill the transmission oil according to 23/37 , 23/17 and 23/21 .
5. Drive the car for about 5 minutes at different speeds and accelerations.
6. Repeat step 3 to step 5 (except place new oil filter) for 2 or 3 times until the noise disappears. The
‘gegege’ sound should be disappear as well as the ‘zhi~’ sound.
7. The ‘zhi~’ sound can disappear by heating up the clutch by doing stall test:
Shift to ‘D’ and apply throttle.
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.
T
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.
AF
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 23/33 )
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.
R
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
D
replace other parts of the car which are easier to replace first.
Use following chart to locate the origin of the noise:

CVT 23
T
AF
DOINC023R11063
R
SHOCK AND NO CREEP PROBLEMS WCH023TSHOT11169
SHOCKS
D
Problem description:
During driving in D, the small vibrations or shocks can be felt.
Check and repair:
There could be many possibilities for this problem:
No Problem Solution
1 Clutch adaptation not fully finished Refer to page 23/80 .
2 Water or contaminated oil inside Refer to page 23/76 .
the transmission
3 Primary speed sensor problem Replace by refer to page 23/46 .
4 Hydraulic unit problem Replace by refer to page 23/43 and 23/80 (redo clutch ad-
aptation procedure).
5 Secondary speed sensor problem Replace by refer to page 23/45 .
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:

23 CVT
No Problem Solution
1 Fault code active Refer to page 23/75 .
2 If problem happens in cold condition Refer to page 23/80 .
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 23/43 and 23/80 (redo
clutch adaptation procedure).
DIAGNOSTIC FUNCTION WCH023TSHOT11170
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
DOIQC023R11044
T A CVT warning lamp

AF
FREEZE FRAME DATA WCH023TSHOT11171
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.
R
DISPLAY ITEM LIST

No PADT-II display Unit / Display Remark
1 Brake status OFF/ON
D
2 Brake fault OK/FAIL -

3 Shift lock OFF/ON
4 Engine coolant temperature °C
Temperature value

CVT 23

5 ABS signal fault 0: ABS activation
1: ABS braking
2: Anti slip loop controller (ASR)
active
3: Electronic Differential Cut/Lock
(EDS) active
4: Electronic Stability Program (ESP)
active
9: Brake pedal stroke
10: Quality flag brake pedal stroke
11: Mileage (km)
12: Brake light
13: Quality flag brake light
14: Handbrake Signal from ABS sys-
15: Quality flag handbrake tem when the diagnos-
16: Brake pressure is code is generated
T
17: Quality flag brake pressure
18: Wheel speed front left
AF
19: Wheel speed front right
20: Wheel speed rear left
21: Wheel speed rear right
22: Quality flag wheel speed front
left
23: Quality flag wheel speed front
R
right
25: Quality flag wheel speed rear
left
D
26: Quality flag wheel speed rear

right
6 Missing ABS message(s) — Integer value

23 CVT

7 EMS signal fault 0: Engine torque
1: Driver demanded engine torque
2: Engine torque loss
3: Quality flag engine torque
4: Quality flag driver demanded
engine torque
5: Quality flag engine torque loss
6: Engine speed
7: Quality flag engine speed
8: Throttle
9: Acceleration pedal
10: Quality flag acceleration pedal
11: Mileage (km)
12: Brake light Signal from EMS sys-
tem when the diagnos-
13: Quality flag brake light is code is generated
T
14: Handbrake
15: Quality flag handbrake
16: Maximum engine torque
AF
17: Torque reduction confirmation
18: Target wheel torque
20: Engine adaptation
21: Engine temperature
22: Quality flag engine temperature
R
23: Cruise control speed

26: Environmental pressure
28: Quality flag environmental
D
pressure
29: Engine idle target speed
8 Active error reactions (1/2) — Integer value
9 Active error reactions (2/2) — Integer value
10 Commanded current for pres- mA
Current value
sure regulator of pulley 1
Current value
sure regulator of pulley 2
Current value
sure regulator of clutch
13 Target ratio — Decimal value
14 Ratio gradient — Ratio gradient value
15 Engine torque (corrected) Nm Torque value
16 Actual current pressure regu- mA
Current value
lator pulley 1
Current value
lator pulley 2

CVT 23

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

Pressure value
21 Measured pulley 2 pressure bar Pressure value

22 Position sensor - single line 0: line A short to ground
status 1: line A short to battery
2: line A open load
3: line A plausibility
4: line B short to ground
5: line B short to battery
6: line B open load Signal from position
7: line B plausibility sensor when the dia-
8: line C short to ground gnosis code is gener-
T
9: line C short to battery
10: line C open load
ated
AF
11: line C plausibility
12: line D short to ground
13: line D short to battery
14: line D open load
15: line D plausibility
23 ZF reset counter — Integer value
R
24 SV reset counter — Integer value

25 TRAP reset counter — Integer value
26 TSK reset counter — Integer value
D
27 Hotmode diagnosis status 0: High transmission temperature

1: Request to activate engine fan
4: Transmission ratio control - limit- Hotmode diagnosis
ing maximum engine speed status when the dia-
5: Switch off tip function gnosis code is gener-
6: Request engine torque reduction ated
7: Transmission ratio control - limit-
ing minimum engine speed

23 CVT

28 Sensor signals status 0: Primary pulley speed substituted
1: Primary pulley speed temporary
undefined
2: Primary pulley speed undefined
undefined
3: Secondary pulley speed substi-
tuted
4: Secondary pulley speed tempor-
ary undefined
5: Secondary pulley speed un-
defined
6: Secondary pressure substituted Sensor signal status
7: Secondary pressure temporary when the diagnosis
undefined code is generated
8: Secondary pressure undefined
9: Lever position substituted
T
10: Lever position temporary un-
defined
11: Lever position undefined
AF
12: Transmission oil temperature
substituted
temporary undefined
undefined
R
29 Vehicle speed based on out- km/h

Speed value
put speed
30 High side voltage V Voltage value
D
31 Ignition voltage V Voltage value

32 Sensor supply voltage 5V V Voltage value
33 Sensor supply voltage 8.4V V Voltage value
34 Mileage km Mileage value
35 Battery voltage V Voltage value
36 External WTD reset counter — Integer value
37 Internal WTD reset counter — Integer value
38 Lever position for freeze 0: Undefined / error
frame 1: Position L
4: Position D Gear lever position
when the diagnosis
5: Position N code is generated
6: Position R
7: Position P

CVT 23

39 Clutch status 0: Undefined
1: Open
2: Filling
3: Applied
4: Creeping
5: Take off Clutch status when the
diagnosis code is gen-
6: Closed erated
7: Roll out
8: Opening
9: Opening SW
10: Opening ABS
11: Opening blocking wheels (BLR)
40 Expected clutch pressure bar Pressure value
41 Engine speed rpm Engine speed value
42 Vehicle speed calculated by km/h
Speed value
T
TCU
43 Throttle position % Integer value
44 Pulley 1 speed rpm Pulley 1 speed value
AF
45 Output speed rpm Output speed value
46 Clutch slip rpm Only positive value is
used
47 PWM duty cycle for Pulley 1 % Integer value
48 PWM duty cycle for Pulley 2 % Integer value
R
49 PWM duty cycle for Clutch % Integer value

50 Transmission oil temperature °C
Temperature value
51 Gear ratio — Ratio value

D
52 Lever position 0: Unknown

1h: First Manual Gear
2h: Second Manual Gear
3h: Third Manual Gear
4h: Fourth Manual Gear
5h: Fifth Manual Gear
6h: Sixth Manual Gear Gear lever position
10h: R (reverse) when the diagnosis
20h: Z1 code is generated
21h: Z2
22h: Z3
23h: Z4
41h: SAT; First Gear
42h: SAT; Second Gear
43h: SAT;Third Gear

23 CVT

53 EOL Clutch Adaptation Error 0: No Error
1: Unstable Engine torque
Status of clutch adapt-
2: Air-cond ON
ation EOL when the
4: Pressure too high
diagnosis code is gen-
8: Engine speed too low
erated
16: Engine speed too high
32: Too many abortions
54 Engine torque (CAN) Nm Torque value
55 Last mileage counter after km
Integer value
engine off
56 Status of clutch adaption EOL 00b : Adaption values of Clutch
forward - reverse Not finished
01b : Only Adaption values of Clutch Status of clutch adapt-
forward finished ation EOL when the
10b : Only Adaption values of Clutch diagnosis code is gen-
reverse finished erated
11b: Adaption values of Clutch for-
ward - reverse finished
CLUTCH ADAPTATION PROCEDURE

INTRODUCTION
T WCH023TSHOT11172
AF
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.
R
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.
D
No Pre-condition ECU target value

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

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

4. When something disturbs the clutch adaptation, fault code P1774 will be triggered and the CVT
warning lamp will constant activated.
DOIQC023R11044
Symbol Description
A CVT warning lamp
T
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
AF
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.
R
D

23 CVT
T
AF
R
D
DOINC023R11064
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.

CVT 23
9. Perform the next actions:

• Vehicle speed = 0 km/h (0 mph).
• Throttle pedal not applied.
• Foot brake has to be applied all the time.
• Gear lever in “Reverse” position.
10. The EOL clutch adaptation procedure will start automatically.
11. When something disturbs the clutch adaptation, fault code P1774 will be triggered and the CVT
warning lamp will constant activated.
Symbol
T Description
DOIQC023R11044
AF
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.
R
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.
D

23 CVT
T
AF
R
D
DOINC023R11065

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

1 Unstable engine torque
2 Air-conditioning is switched on
4 Pressure too high
8 Engine speed too low
16 Engine speed too high
32 Too many abortions
Problem Possible Cause Action
Transmission oil temperature is 1. Allow the transmission to heat
below 30 °C (86 °F) during adapta- up (engine on).
tion process.
T
Transmission oil temperature ex-
2.
1.
Restart adaptation procedure.
Allow the transmission to cool
AF
Test procedure has to be ceeds 80 °C (176 °F) during adapt- down (engine off).
aborted after 120 seconds ation process. 2. Restart adaptation procedure.
without the clutch adaptation 1. Allow engine to heat up (en-
bit being set. Engine temperature is below 60
gine on).
°C (140 °F).
2. Restart adaptation procedure.
Foot brake has been released for 1. Make sure that foot brake is
R
a short while during adaptation always applied.

process. 2. Restart adaptation procedure.
1. Improve engine torque stabil-
P1774: EOL clutch adaptation Unstable engine torque during ity. Make sure engine adapta-
D
error = 1 adaptation process. tion is completed successfully.

1. Switch off the air-conditioning
P1774: EOL clutch adaptation during complete adaptation
Air conditioning is switched on.
error = 2 process.
1. Check if transmission can
transmit torque when gear
Clutch pressure is increase which lever is put into D or R.
P1774: EOL clutch adaptation makes transmission load to the 2. Check if engine torque signal
error = 4 engine, but the engine torque is OK.
signal does not increase. 3. Make sure engine adaptation
is completed successfully.
1. Improve engine rpm stability.
P1774: EOL clutch adaptation Engine speed is too low during 2. Make sure engine adaptation
error = 8 adaptation process. is completed successfully.

23 CVT
Problem Possible Cause Action

1. Improve engine rpm stability.
P1774: EOL clutch adaptation Engine speed is too high during 2. Make sure engine adaptation
error = 16 adaptation process. is completed successfully.
The adaptation process is some-
times interrupted caused by a 1. Make sure that all the auxiliar-
sudden engine torque change ies are not switched on/off
P1774: EOL clutch adaptation
which can be caused by auxiliaries during the complete adapta-
error = 32
(turned on or off). E.g: Fan, steer, tion process.
window opening/closing, heating, 2. Restart adaptation procedure.
etc.
SPECIAL FUNCTIONS WCH023SPROC11069
PRE-CAUTION FOR OPERATING PADT-II

1. When battery voltage is low, no detection of failure is possible. Be sure to check the battery for
voltage and other conditions before starting the tests.
2. Connection and disconnection of the PADT–II should always be made with the ignition switch in
T
the OFF position.
3. Fault code can only be erased when ignition switch is in the ON position. After deleting, switch
to “OFF” position and wait 30 sec. before turning ⇒ “ON”the ignition.
AF
R
D
DOIQC023R11045
4. Connect PADT-II (VCI) to diagnostic connector (the position of the diagnostic connector varies
between models).
Symbol Description
A PADT-II vehicle communication 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.

CVT 23
PRE-CONDITION CHECK OF CLUTCH ADAPTATION USING PADT-II
T
AF
R
DOIQC023R11046
1. Go to “Data List”.
The system will display as below :
D
Select Subsystem
Default List
Predefined
2. Go to “Select Subsystem” and a list of correspond subsystems will appear in the PADT-II interface.
3. Select one subsystem for Data List: “Power Train System; Transmission Subsystem; PUNCH_CVT
ECU Identification” as shown in the illustration.

23 CVT
T
AF
DOIQC023R11047
R
4. Go to “Default List” and list of current condition for CVT will appear. From there, check the pre-
conditions of clutch adaptation:
No Parameter name ECU target value

D
1 Engine speed >200 rpm

2 Engine coolant temperature >60 °C (140 °F)
3 Oil temperature 30-80 °C (86-176 °F)
4 Vehicle speed 0 km/h (0 mph)
5. If all pre-conditions have been fulfilled, then proceed to the clutch adaptation procedure, otherwise
wait until the pre-conditions are fulfilled.
CVT CLUTCH ADAPTATION USING SPECIAL FUNCTION IN PADT-II WCH023SPROC11070

Clutch Adaptation To ensure that the Transmission After:
Control Unit (TCU) adapted to the 1. Uploading new software in the TCU or
CVT prior to first use. Once this 2. Replacement of transmission or
procedure is completed, lifetime 3. Replacement of TCU
adaptation occurs automatically.

CVT 23
T
AF
DOIQC023R11048
R
1. Go to “Active Tests”.
Select Subsystem
Special Functions
D
Actuator Tests

23 CVT
T
AF
DOIQC023R11049
R
2. Go to “Select Subsystem” and a list of corres-

pond subsystems will appear in the PADT-II
interface.
3. Select one subsystem for Active Tests: “Power
D
Train System; Transmission Subsystem;

PUNCH_CVT ECU Identification” as shown in
the illustration.

CVT 23
T
AF
DOIQC023R11050
R
4. Go to “Special Functions” and list of special

functions for CVT will appear.
5. Then, click on “Clutch Adaptation”.
6. Read the instruction given carefully and go
D
to “Next” button.
DOINC023R11199

23 CVT
7. Go to “Reset Adaptation” in case of TCU was

adapted before, for example upload new
software in the TCU or replacement of
transmission.
DOINC023R11200
8. After finish reset adaptation, click to “Back”

button to return to Start Adaptation.
T
AF
DOINC023R11201
9. Then go to “Start Adaptation”.

R
D
DOINC023R11202
10. Read the instruction given carefully. The en-

gine must be running in order to perform
this test. Turn the engine on and go to
“Next” button.
DOINC023R11203

CVT 23
11. After engine is turned on and all pre-condi-

tions have been fulfilled, go to “Next” button
to proceed with the test.
NOTE
Refer to WCH023SPROC11066 to check the
pre-conditions of clutch adaptation using
PADT-II.
DOINC023R11204
12. Read the instruction given carefully. Turn the

air-conditioner off. Press brake all the time
during adaptation and shift the gear to “D”
(DRIVE position). Then, press the “Next”
button to continue.
T
AF
DOINC023R11205
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 to
R
proceed to next step.

D
DOINC023R11206
13. Shift the gear to “R” (REVERSE position) and

press “Next” button to continue.
DOINC023R11207

23 CVT
When the clutch adaptation in this gear is

completed, the engine will rev up to 1500
rpm for a short time. Then shift gear to “P”
(PARKING position) or “N” (NEUTRAL posi-
tion).
DOINC023R11208
14. Clutch adaptation process completed success-

fully. Press back button to return to Main
Menu.
T
AF
DOINC023R11209
SELF DIAGNOSIS WCH023TSHOT11173

R
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
D
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.

CVT 23
No Item Description
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 km/h (55.92 mph).
• The gearbox will shift but within a basic driving strategy.
T
• 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.
AF
R
D

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

2. Warning lamp
sensor fault 4. Sensor defective
5. TCU malfunction
Secondary 1. Wire harness problem
D
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
lem

CVT 23
Dia-
Code Item play
No
Secondary 2. Short circuit to battery
1. High side off
8 P0840 pressure sensor 3. Open circuit
2. Warning lamp
5. TCU malfunction
2. Short circuit to battery
Pressure sensor 1. High side off
9 P0641 3. Open circuit
supply fault 2. Warning lamp
4. Sensor defective
5. TCU malfunction
1. Too low pressure
Secondary
2. Oil level problem
pressure
3. Oil type problem
Secondary pul-
4. Clutch adaptation not com- 1. High side off
10 P1765 ley pressure
plete 2. Warning lamp
too low
T
5. Too low torque from engine
7. Oil pump defective
AF
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
R
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
D
1. Transmission cable harness

problem
Drive mode 1. Warning lamp
13 P0706 Drive mode sensor single 2. Substitute lever po-
lem
sensor line error sition
3. Drive mode sensor failure
4. TCU malfunction
problem
Drive mode
2. Vehicle cable harness prob- 1. High side off
14 P0705 sensor multiple
lem 2. Warning lamp
lines error
4. TCU malfunction

23 CVT
Dia-
Code Item play
No
High side Short
1. Short circuit to battery 1. High side off
15 P0659 Circuit to Bat-
2. TCU malfunction 2. Warning lamp
tery
High side Short
Circuit to 1. High side off
Ground or 2. Warning lamp
3. TCU malfunction
Open Circuit
Double fault
High side 1. High side off
17 P0701 requiring high TCU malfunction
2. Warning lamp
side open
Battery or high 1. Battery problem
1. High side off
18 P0882 side voltage 2. Highside problem
2. Warning lamp
too low 3. TCU malfunction
1. High side off
19 P0883 side voltage 2. Highside problem
T
2. Warning lamp
too high 3. TCU malfunction
Watchdog test
1. High side off
20 P0702 Software in- failed (during TCU malfunction
AF
2. Warning lamp
compatibil- init)
ity Software com-
Invalid combination of TCU 1. High side off
21 P0602
patibility error
hardware and software 2. Warning lamp
1. Flashing process is interrup-
EEPROM error 1. High side off
22 P0603 ted
(checksum) 2. Warning lamp
2. Hardware failure of TCU
R
Data check of 1. Flashing process is interrup-

Data check 1. High side off
23 P0604 internal RAM ted
and check- 2. Warning lamp
failed 2. Hardware failure of TCU
sum error
D
Checksum er-
1. Flashing process is interrup-
ror — data or 1. High side off
24 P0605 ted
code area in 2. Warning lamp
2. Hardware failure of TCU
ROM

CVT 23
Dia-
Code Item play
No
EDS1 (primary
pulley) Short 1. Short circuit to ground 1. High side off
25 P0962
Circuit to 2. Hydraulic unit defective 2. Warning lamp
Ground
EDS1 (primary
pulley) Short 1. Short circuit to battery 1. High side off
26 P0963
Circuit to Bat- 2. Hydraulic unit defective 2. Warning lamp
tery
EDS1 (primary
1. Open circuit 1. High side off
27 P0960 pulley) Open
2. Hydraulic unit defective 2. Warning lamp
Circuit
EDS2 (second-
ary pulley) 1. Short circuit to ground 1. High side off
28 P0966
Short Circuit to 2. Hydraulic unit defective 2. Warning lamp
Ground
29 P0967
EDS2 (second-
ary pulley)
Short Circuit to
T
1. High side off
2. Warning lamp
AF
EDS (Pres- Battery
sure regulat-
EDS2 (second-
or) 1. Open circuit 1. High side off
30 P0964 ary pulley)
Open Circuit
EDS3 (clutch)
1. Short circuit to ground 1. High side off
31 P0902 Short Circuit to
R

Ground
EDS3 (clutch)
1. Short circuit to battery 1. High side off
32 P0903 Short Circuit to
D
Battery
EDS3 (clutch) 1. Open circuit 1. High side off
33 P0900
Open Circuit 2. Hydraulic unit defective 2. Warning lamp
problem
EDS current 2. Vehicle cable harness prob- 1. High side off
34 P1761
fault lem 2. Warning lamp
3. Hydraulic unit failure
4. TCU malfunction
1. High side off
35 P1762 Current stuck TCU malfunction
2. Warning lamp
Shift lock Short
36 P0930 Circuit to
Ground
Shift lock Shift lock Short
Circuit to Bat- 1. High side off
tery or Open 2. Warning lamp
3. TCU malfunction
Circuit

23 CVT
Dia-
Code Item play
No
Backlight Short
38 P1768 Circuit to
Ground
Backlight Backlight Short
Circuit to Bat- 1. High side off
tery or Open 2. Warning lamp
3. TCU malfunction
Circuit
Operation
Operation 2. Oil type problem 1. High side off
40 P0868 readiness time-
readiness 3. Oil pump defective 2. Warning lamp
out
1. Clutch adaptation not com-
Clutch (for- plete
1. High side off
41 P0811 ward or re- 2. Oil level problem
2. Warning lamp
verse) slipping 3. Oil type problem
Clutch
T
2. Oil type problem
AF
Clutch temper- 3. Clutch adaptation not com- 1. Warning lamp
42 P2787
ature too high plete 2. Clutch open
4. Throttle valve defective
5. TCU malfunction
2. Oil type problem
Ratio control 1. High side off
R
43 P0730 Ratio control 3. Sensor or hydraulic unit de-

fault 2. Warning lamp
fective
1. Idle speed controller prob-
D
Engine speed lem

44 P1770 Warning lamp
too low 2. Check engine problem
3. Throttle body problem
Engine Hardwired en- 1. Engine problem
45 P0727 speed gine speed un- 2. Sensor defective Warning lamp
plausible 3. TCU malfunction
Powertrain
1. High side off
46 P0219 speed out of Fuel cut off problem
2. Warning lamp
range
1. Torque of the engine is too
big
2. ECU malfunction
Insufficient Insufficient
4. Oil type problem 1. Warning lamp
47 P0944 clamping clamping force
5. Clutch adaptation not com- 2. Clutch open
force (VSM) (VSM)
plete

CVT 23
Dia-
Code Item play
No
AT mode AT mode sig- 2. Open circuit
48 P1772 Warning lamp
signal nal error 3. Stepper motor switch mal-
function
EOL Clutch Ad-
49 P080A aption Not Fin- Clutch adaptation not complete Warning lamp
End Of Line ished
(EOL) clutch End Of Line
adaptation (EOL) clutch
50 P1774 Clutch adaptation error Warning lamp
adaptation er-
ror
1. Brake signal wiring problem
Brake signal 1. Warning lamp
51 P0571 Brake signal 2. Brake switch problem
error 2. Brake signal on
3. TCU malfunction
Vehicle config-
T
Vehicle con- Invalid combination of TCU 1. High side off
52 U0301 uration mis-
figuration hardware and software 2. Warning lamp
match
1. Increased clamping
AF
level 0
ABS function 2. Substitute detec-
53 U0415 ABS function ABS system problem
error tion function of
blocked and spin-
ning wheels
R
D

23 CVT
Dia-
Code Item play
No
1. Warning lamp
2. Emergency mode
active
3. No manual mode
level 1 (highest)
5. Substitute detec-
tion function of
blocked and spin-
ning wheels
6. Activate internal
driving strategy
7. Substitute engine
speed
1. Short circuit between CAN
54 U0001 CAN bus off high and CAN low
torque
T
2. TCU malfunction
cooling water tem-
perature
AF
10. Brake signal on
11. Accelerator pedal
value fixed
12. Substitute front
CAN left wheel speed
13. Substitute front
R
right wheel speed

14. Substitute rear left
wheel speed
15. Substitute rear
D
right wheel speed

level 0
tion function of
blocked and spin-
ning wheels
CAN ABS com- 1. ABS controller failure
3. Substitute front
55 U0121 munication 2. CAN connection problem
left wheel speed
failed from ABS controller
4. Substitute front
right wheel speed
wheel speed
6. Substitute rear
right wheel speed
CAN ECU com- 1. Engine controller failure
56 U0100 munication 2. CAN connection problem
failed from engine controller

CVT 23
Dia-
Code Item play
No
1. Warning lamp
2. Emergency mode
active
3. No manual mode
level 0
driving strategy
speed
torque
cooling water tem-
perature
9. Accelerator pedal
T value fixed
10. Stop transmitting
on CAN
AF
CAN engine 1. Warning lamp
1. Motor speed sensor defective
57 U1012 speed signal 2. Substitute engine
2. Sensor wiring problem
error speed
CAN accelerat- 1. Accelerator pedal sensor de- 1. Warning lamp
58 U1013 or pedal signal fective 2. Accelerator pedal
error 2. Sensor wiring problem value fixed
R
1. Warning lamp
2. Emergency mode
active
CAN engine
D
3. No manual mode
59 U1014 torque signals EMS controller problem
error
driving strategy
torque
level 0
CAN wheel 1. Wheel speed sensor defect-
tion function of
60 U1016 speed error - ive
blocked and spin-
front left 2. Sensor wiring problem
ning wheels
3. Substitute front
left wheel speed
front right 2. Sensor wiring problem

23 CVT
Dia-
Code Item play
No
level 0
tion function of
blocked and spin-
ning wheels
3. Substitute front
right wheel speed
level 0
tion function of
blocked and spin-
rear left 2. Sensor wiring problem
ning wheels
T
wheel speed
level 0
AF
tion function of
blocked and spin-
rear right 2. Sensor wiring problem
ning wheels
3. Substitute rear
right wheel speed
R
ROAD TEST WCH023TSHOT11174
No Conditions for Test/Operation Judgement Check item Diagnos- Reference for checking
test/operation standard is code procedure in case of
D
No. error
1 Ignition switch: Ignition switch Data list No. 18 ECU power - Communication with
LOCK (OFF) (1) ON and 19 supply the PADT—II is not
(1) Battery possible (Refer to page
voltage 23/255 )
2 Ignition switch: Selector lever Data list No. 12, Drive mode P0651 Malfunction of drive
ON position 13 and 14 (Lever sensor P0706 mode sensor (Refer to
Engine: (1) P position) P0705 page 23/143 )
Stopped (2) R (1) P
(3) N (2) R
(4) D (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 on signal (Refer to page 23/222 )
Engine: mode button outer panel
Stopped at gear shift to gearshift
switch to A/T
mode

CVT 23
No. error
4 Ignition switch: Accelerator Data list No. 50 APS U0001 CAN time-out error
ON pedal and 52 (Throttle U0100 (Engine) (Refer to page
Engine: (1) Fully closed position) 23/235 )
Stopped (2) Depressed (1) 0% .
Selector lever (3) Fully (2) Gradually in-
position: P opened creases from (1)
(3) 100%
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 23/228 )
(2) OFF
Brake pedal Data list No. 32 Shift lock P0930 Malfunction of shift
pressed and and 33 (Shift P0931 lock (Refer to page
gear shift lever lock) 23/196 )
position down- ON
shift from P to
T
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 23/217 )
AF
the P or N posi-
tion.
6 Engine warm- Drive the Data list No. 6 CVT oil P0710 Malfunction of CVT oil
ing up vehicle for 15 temperat- temperature sensor
minutes or ure sensor (Refer to page 23/115 )
more to raise
R
the CVT fluid

temperature
from 45 °C
(113 °F) to 100
D
°C (212 °F).
7 Engine: Idling • Selector lever Data list No. 40 Engine P1770 Abnormal engine
position: P and 41 speed P0219 speed (Refer to page
• Accelerator 600 to 800 r/min 23/216 )
pedal fully
closed
Selector lever No abnormal Malfunc- - Shock is experienced
position: P ? R shift shock tion at star- during N to D and/or N
?N?D Delay: 2 seconds tup to R shifting operation.
or less (Refer to page 23/79 )
- Vehicle Creeps in the N
Range. (Refer to page
23/79 )
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 23/133 )
Data list No. 21, Primary P0962 Malfunction of primary
22 and 23 pressure P0963 pressure regulator
0.45 - 0.75 A regulator P0960 (Refer to page 23/165 )

23 CVT
No. error
Data list No. 24, Secondary P0966 Malfunction of second-
25 and 26 pressure P0967 ary pressure regulator
0.45 - 0.75 A regulator P0964 (Refer to page 23/174 )
Data list No. 27, Clutch pres- P0902 Malfunction of clutch
28 and 29 sure regu- P0903 pressure regulator
0.45 - 0.75 A lator P0900 (Refer to page 23/183 )
8 Selector lever Running Data list No. 4 Primary P2765 Malfunction of primary
position: D Nearly the same speed speed sensor (Refer to
as the speedo- sensor page 23/121 )
meter display
Data list No. 6 Secondary P0720 Malfunction of the sec-
Nearly the same speed ondary speed sensor
as the speedo- sensor (Refer to page 23/127 )
meter display
9 Selector lever Selector lever Data list No. 44 Poor accel- P1772 Poor acceleration or in-
position: position (1) 1st eration or complete shifting oper-
Stepped A/T
(SAT) mode
(1) Stopped
while idling
the engine.
(2) 2nd
(3) 3rd
(4) 4th
Tincomplete
shifting op-
eration
ation (Refer to page
23/222 )
AF
(2) Driving at a (5) 5th
constant speed
of 30 km/h in
2nd gear
(3) Driving at a
constant speed
R
of 35 km/h in
3rd gear
(4) Driving at a
constant speed
D
of 40 km/h in
4th gear
(5) Driving at a
constant speed
of 50 km/h in
5th gear
INSPECTION CHART FOR DIAGNOSIS CODE WCH023TSHOT11175
Diagnosis
No Diagnostic Item Reference Page
Code No
1 P0710
2 P0218 Oil temperature Refer to page 23/115
3 P1767
4 P2765
Primary pulley speed Refer to page 23/121
5 P2766
6 P0720
Secondary pulley speed Refer to page 23/127
7 P0721

CVT 23
Diagnosis
Code No
8 P0840
9 P0641
Secondary pressure Refer to page 23/133
10 P1765
11 P1766
12 P0651
13 P0706 Drive mode sensor Refer to page 23/143
14 P0705
15 P0659
16 P0658
17 P0701 High side Refer to page 23/149
18 P0882
19 P0883
20 P0702
Software incompatibility Refer to page 23/164
21 P0602
T
22 P0603
23 P0604 Data check and checksum error Refer to page WCH023TSHOT12002
24 P0605
AF
25 P0962
26 P0963
27 P0960
28 P0966
29 P0967
R
30 P0964 EDS (Pressure regulator) Refer to page 23/165

31 P0902
32 P0903
D
33 P0900
34 P1761
35 P1762
36 P0930
Shift lock Refer to page 23/196
37 P0931
38 P1768
Backlight Refer to page 23/204
39 P1769
40 P0868 Operation readiness Refer to page 23/211
41 P0811
Clutch Refer to page 23/211
42 P2787
43 P0730 Ratio control Refer to page 23/214
44 P1770
45 P0727 Engine speed Refer to page 23/216
46 P0219
47 P0944 Insufficient clamping force Refer to page 23/219
48 P1772 AT mode signal Refer to page 23/222

23 CVT
Diagnosis
Code No
49 P080A
End Of Line (EOL) clutch adaptation Refer to page 23/225
50 P1774
51 P0571 Brake signal Refer to page 23/228
52 U0301 Vehicle configuration Refer to page 23/232
53 U0415 ABS function Refer to page 23/233
54 U0001
55 U0121
56 U0100
57 U1012
58 U1013
CAN Refer to page 23/235
59 U1014
60 U1016
61 U1017
62 U1018
T
63 U1019
AF
R
D

CVT 23
P0710: OIL TEMPERATURE SENSOR FAULT WCH023TSHOT11176
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.
T
AF
R
D
DOIQC023R11051
CONNECTOR: B-40 CONNECTOR: C-27

23 CVT
OIL TEMPERATURE SENSOR
DOINC023R11171
Fault code PADT–II display Reaction from TCU Probable cause
1. Warning lamp 2. Short circuit to battery
T
Oil temperature
P0710 2. Substitute transmission oil 3. Open circuit
sensor fault 4. Sensor defective
temperature
5. TCU malfunction
AF
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).
R
D

CVT 23
T
AF
R
D
DOIQC023R11071

23 CVT
P0218: HIGH OIL TEMPERATURE WCH023TSHOT11177
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.
DOINC023R11171
Fault code PADT–II display
T
Reaction from TCU Probable cause
AF
High oil temperat-
P0218 Warning lamp Oil cooler problem
ure
1. Warming up
Dynamic data
R
display
comes 70-90 °C (158-194 °F).
D

CVT 23
T
AF
DOIMC023R11202
R
P1767: CRITICAL OIL TEMPERATURE WCH023TSHOT11178
OPERATION
D
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.
DOINC023R11171

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

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

CVT 23
P2765: PRIMARY PULLEY SPEED SENSOR FAULT WCH023TSHOT11179
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.
T
AF
R
D
DOIQC023R11052

23 CVT
PRIMARY PULLEY SPEED SENSOR
DOINC023R11175
T
Primary pulley 1. High side off 3. Open circuit
P2765
speed sensor fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction
AF
1. Selector lever position: D
Dynamic data Primary pulley Approximately similar as the ta-
2. Driving at constant speed
display speed chometer display
of 50 km/h (31.07 mph)
R
D

CVT 23
T
AF
R
D
DOIQC023R11072

23 CVT
P2766: PRIMARY PULLEY SPEED UNPLAUSIBLE WCH023TSHOT11180
OPERATION
The primary pulley speed sensor detects the input revolution speed and sends a signal to the CVT-
TCU.
CVT-TCU determines that the malfunction is present when the primary pulley speed sensor value
reading.
T
AF
R
D
DOIQC023R11053

CVT 23
CONNECTOR: C-11 PRIMARY PULLEY SPEED SENSOR
T
AF
R
1. Wire harness problem
D
2. TCU malfunction
3. Sensor defective
Primary pulley 1. High side off 4. Transmission cable harness
P2766
speed unplausible 2. Warning lamp problem
lem

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

23 CVT
T
AF
R
D
DOIQC023R11073

CVT 23
P0720: SECONDARY PULLEY SPEED SENSOR FAULT WCH023TSHOT11181
OPERATION
The secondary pulley speed sensor detects the output revolution speed and sends a signal to the CVT-
TCU.
CVT-TCU determines that the malfunction is present when the secondary pulley speed sensor value
reading.
T
AF
R
D
DOIQC023R11054

23 CVT
SECONDARY PULLEY SPEED SENSOR
DOINC023R11177
T
Secondary pulley 1. High side off 3. Open circuit
P0720
speed sensor fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction
AF
1. Selector lever position: D
Dynamic data Secondary pulley
2. Driving at constant speed Tachometer display X 5.76 (rpm)
display speed
of 50 km/h (31.07 mph)
R
D

CVT 23
T
AF
R
D
DOIQC023R11074

23 CVT
P0721: SECONDARY PULLEY SPEED UNPLAUSIBLE WCH023TSHOT11182
OPERATION
The secondary pulley speed sensor detects the output revolution speed and sends a signal to the CVT-
TCU.
CVT-TCU determines that the malfunction is present when the secondary pulley speed sensor value
reading.
T
AF
R
D
DOIQC023R11053

CVT 23
CONNECTOR: C-11 SECONDARY PULLEY SPEED SENSOR
T
AF
R
1. Wire harness problem
D
2. TCU malfunction
3. Sensor defective
Secondary pulley 1. High side off 4. Transmission cable harness
P0721
speed unplausible 2. Warning lamp problem
lem

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

23 CVT
T
AF
R
D
DOIQC023R11075

CVT 23
P0840: SECONDARY PRESSURE SENSOR FAULT WCH023TSHOT11183
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.
T
AF
R
D
DOIQC023R11055

23 CVT
SECONDARY PRESSURE SENSOR
DOINC023R11170
T
Secondary pressure 1. High side off 3. Open circuit
P0840
sensor fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction
AF
1. Commanded pul-
Dynamic data ley 2 pressure Pulley 2 pressure operation
Vehicle being driven
display 2. Measured pulley 2 Approximately similar value
pressure
R
D

CVT 23
T
AF
R
D
DOIQC023R11076

23 CVT
P0641: PRESSURE SENSOR SUPPLY FAULT WCH023TSHOT11184
OPERATION
T
AF
R
D
DOIQC023R11055

CVT 23
DOINC023R11170
T
Pressure sensor supply 1. High side off 3. Open circuit
P0641
fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction
AF
Dynamic data
5.0 V sensor voltage Ignition ON 5.0 V
display
R
D

23 CVT
T
AF
R
D
DOIQC023R11077

CVT 23
P1765: SECONDARY PULLEY PRESSURE TOO LOW WCH023TSHOT11185
OPERATION
DOINC023R11170
T
AF
1. Too low pressure
3. Oil type problem
Secondary pulley 1. High side off 4. Clutch adaptation not com-
P1765 plete
pressure too low 2. Warning lamp
R

Function PADT–II display Check Condition Standard Value

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

23 CVT
T
AF
R
D
DOIMC023R11162

CVT 23
P1766: SECONDARY PULLEY PRESSURE TOO HIGH WCH023TSHOT11186
OPERATION
DOINC023R11170
T
AF
1. Too high pressure
Secondary pulley 1. High side off 3. Oil type problem
P1766
pressure too high 2. Warning lamp 4. Hydraulic unit defective
R

pulley 2 pres-
Dynamic data Pulley 2 pressure operation
D

2. Measured pul-
ley 2 pressure

23 CVT
T
AF
R
D
DOIMC023R11171

CVT 23
P0651: DMS AND SPEED SENSOR SUPPLY FAULT WCH023TSHOT11187
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.
T
AF
R
D
DOINC023R11107

23 CVT
PRIMARY PULLEY SPEED SENSOR SECONDARY PULLEY SPEED SENSOR
DRIVE MODE SENSOR (DMS)
T
AF
DOINC023R11176
R
D

DMS and speed sensor 1. High side off 3. Open circuit
P0651
supply fault 2. Warning lamp 4. Sensor defective
5. TCU malfunction

Dynamic data
8.4 V sensor voltage Ignition ON 8.4 V
display

CVT 23
T
AF
R
D
DOINC023R11130

23 CVT
P0706: DRIVE MODE SENSOR SINGLE LINE ERROR WCH023TSHOT11188
OPERATION
present or not.
T DOINC023R11176
AF
problem
Drive mode sensor 1. Warning lamp 2. Vehicle cable harness
P0706 problem
single line error 2. Substitute lever position
R
4. TCU malfunction
D

CVT 23
T
AF
DOIMC023R11226
R
P0705: DRIVE MODE SENSOR MULTIPLE LINES ERROR WCH023TSHOT11189
OPERATION
D
present or not.
DOINC023R11176

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

CVT 23
P0659: HIGH SIDE SHORT CIRCUIT TO BATTERY WCH023TSHOT11190
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).
T
AF
R
D
DOIQC023R11057

23 CVT
EDS1 (PRIMARY PRESSURE REGULATOR), EDS2 (SECONDARY PRESSURE REGULATOR) AND EDS3
(CLUTCH PRESSURE REGULATOR)
DOIQC023R11099
High side Short 1. High side off 1. Short circuit to battery
T
P0659 2. TCU malfunction
Circuit to Battery 2. Warning lamp

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

CVT 23
T
AF
DOIQC023R11079
R
D

23 CVT
P0658: HIGH SIDE SHORT CIRCUIT TO GROUND OR OPEN CIRCUIT WCH023TSHOT11191
OPERATION
T
AF
R
D
DOIQC023R11057

CVT 23
DOIQC023R11099
T
High side Short 1. High side off 2. Open circuit
P0658
Circuit to Battery 2. Warning lamp 3. TCU malfunction
AF
Ignition ON
R
D

23 CVT
T
AF
R
D
DOIQC023R11080

CVT 23
P0701: DOUBLE FAULT REQUIRING HIGH SIDE OPEN WCH023TSHOT11192
OPERATION
T DOIQC023R11099
AF
Double fault re-
1. High side off
P0701 quiring high side TCU malfunction
2. Warning lamp
open
R

Ignition ON
D
DOIMC023R11168
P0882: BATTERY OR HIGH SIDE VOLTAGE TOO LOW WCH023TSHOT11193
OPERATION
(EDS1, EDS2 and EDS3). It monitors if power supply system is normal (3.4 V).

23 CVT
T
AF
R
D
DOIQC023R11058

CVT 23
CONNECTOR: A-36 CONNECTOR: A-08
T
AF
R
D
DOIQC023R11099
1. High side off 2. Highside problem
P0822 side voltage too
2. Warning lamp 3. TCU malfunction
low

23 CVT

Ignition ON
T
AF
R
D

CVT 23
T
AF
R
D
DOIQC023R11081

23 CVT
P0883: BATTERY OR HIGH SIDE VOLTAGE TOO HIGH WCH023TSHOT11194
OPERATION
(EDS1, EDS2 and EDS3). It monitors if power supply system is normal (3.4 V).
T
AF
R
D
DOIQC023R11058

CVT 23
T
AF
R
D
DOIQC023R11099
1. High side off 2. Highside problem
P0883 side voltage too
high

23 CVT

Ignition ON
T
AF
R
D

CVT 23
T
AF
R
D
DOIQC023R11082

23 CVT
P0702: WATCHDOG TEST FAILED (DURING INITIALIZATION) WCH023TSHOT11195
OPERATION
It seems that there was a miscommunication or a software incompatibility with the PADT-II. There is
an internal failure in the transmission control unit.
Watchdog test 1. High side off
P0702 TCU malfunction
failed (during init) 2. Warning lamp
T DOIMC023R11132
AF
R
D

CVT 23
P0962: EDS1 (PRIMARY PULLEY) SHORT CIRCUIT TO GROUND WCH023TSHOT11196
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.
T
AF
R
D
DOIQC023R11057

23 CVT
EDS1 (PRIMARY PRESSURE REGULATOR)
DOINC023R11178
EDS1 (primary pul- 1. Short circuit to ground
1. High side off
P0962 ley) short circuit to 2. Hydraulic unit defective
2. Warning lamp
Function
Ground
PADT–II display Check Condition
1. C o m m a n d e d 1. Warming up
T Standard Value
AF
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-
R
ulator
D

CVT 23
T
AF
DOIQC023R11083
R
D

23 CVT
P0963: EDS1 (PRIMARY PULLEY) SHORT CIRCUIT TO BATTERY WCH023TSHOT11197
OPERATION
valve.
T
AF
R
D
DOIQC023R11057

CVT 23
DOINC023R11178
EDS1 (primary pul- 1. Short circuit to battery
1. High side off
P0963 ley) short circuit to 2. Hydraulic unit defective
2. Warning lamp
Function
Battery
PADT–II display
T
Check Condition
Standard Value
AF
dition
rent of Pulley
1 Pressure Reg-
R
ulator
D

23 CVT
T
AF
DOIQC023R11084
R
D

CVT 23
P0960: EDS1 (PRIMARY PULLEY) OPEN CIRCUIT WCH023TSHOT11198
OPERATION
valve.
T
AF
R
D
DOIQC023R11057

23 CVT
DOINC023R11178
EDS1 (primary pul- 1. High side off 1. Open circuit
P0960 2. Hydraulic unit defective
ley) open circuit 2. Warning lamp
Function PADT–II display Check Condition

T Standard Value
AF
dition
rent of Pulley
1 Pressure Reg-
ulator
R
D

CVT 23
T
AF
DOIQC023R11085
R
D

23 CVT
P0966: EDS2 (SECONDARY PULLEY) SHORT CIRCUIT TO GROUND WCH023TSHOT11199
OPERATION
CVT-TCU determines malfunction by detecting the abnormality in the secondary pressure regulator
valve.
T
AF
R
D
DOIQC023R11057

CVT 23
EDS2 (SECONDARY PRESSURE REGULATOR)
DOINC023R11179
EDS2 (secondary 1. Short circuit to ground
1. High side off
P0966 pulley) short cir- 2. Hydraulic unit defective
2. Warning lamp
Function
cuit to Ground
PADT–II display
T
Check Condition
Standard Value
AF
dition
rent of Pulley
2 Pressure Reg-
R
ulator
D

23 CVT
T
AF
DOIQC023R11086
R
D

CVT 23
P0967: EDS2 (SECONDARY PULLEY) SHORT CIRCUIT TO BATTERY WCH023TSHOT11200
OPERATION
valve.
T
AF
R
D
DOIQC023R11057

23 CVT
DOINC023R11179
EDS2 (secondary 1. Short circuit to battery
1. High side off
P0967 pulley) short cir- 2. Hydraulic unit defective
2. Warning lamp
Function
cuit to Battery
PADT–II display Check Condition
T Standard Value
AF
dition
rent of Pulley
2 Pressure Reg-
R
ulator
D

CVT 23
T
AF
DOIQC023R11087
R
D

23 CVT
P0964: EDS2 (SECONDARY PULLEY) OPEN CIRCUIT WCH023TSHOT11201
OPERATION
valve.
T
AF
R
D
DOIQC023R11057

CVT 23
DOINC023R11179
EDS2 (secondary 1. Open circuit
1. High side off
P0964 pulley) open cir- 2. Hydraulic unit defective
2. Warning lamp
Function
cuit
PADT–II display
T
Check Condition
Standard Value
AF
dition
rent of Pulley
2 Pressure Reg-
R
ulator
D

23 CVT
T
AF
DOIQC023R11088
R
D

CVT 23
P0902: EDS3 (CLUTCH) SHORT CIRCUIT TO GROUND WCH023TSHOT11202
OPERATION
CVT-TCU determines malfunction by detecting the abnormality in the clutch pressure regulator valve.
T
AF
R
D
DOIQC023R11057

23 CVT
EDS3 (CLUTCH PRESSURE REGULATOR)
DOINC023R11180
EDS3 (clutch) short 1. High side off 1. Short circuit to ground
circuit to Ground 2. Warning lamp

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

CVT 23
T
AF
DOIQC023R11089
R
D

23 CVT
P0903: EDS3 (CLUTCH) SHORT CIRCUIT TO BATTERY WCH023TSHOT11203
OPERATION
T
AF
R
D
DOIQC023R11057

CVT 23
DOINC023R11180
EDS3 (clutch) short 1. High side off 1. Short circuit to battery
circuit to Battery 2. Warning lamp
Function PADT–II display
T
Check Condition
Standard Value
AF
tion
rent of Clutch
Pressure Regu-
lator
R
D

23 CVT
T
AF
DOIQC023R11090
R
D

CVT 23
P0900: EDS3 (CLUTCH) OPEN CIRCUIT WCH023TSHOT11204
OPERATION
T
AF
R
D
DOIQC023R11057

23 CVT
DOINC023R11180
EDS3 (clutch) open 1. High side off 1. Open circuit
circuit 2. Warning lamp

T Standard Value
AF
tion
rent of Clutch
Pressure Regu-
lator
R
D

CVT 23
T
AF
DOIQC023R11091
R
P1761: EDS CURRENT FAULT WCH023TSHOT11205
OPERATION
D
CVT-TCU determines malfunction by detecting the abnormality in the pressure regulator current.
DOIQC023R11099

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

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

CVT 23
T
AF
R
D
DOIMC023R11224
P1762: CURRENT STUCK WCH023TSHOT11206
OPERATION
A pressure regulator is a valve that automatically cuts off the flow of transmission oil at a certain
valve.

23 CVT
DOIQC023R11099
1. High side off
P1762 Current stuck TCU malfunction
Function PADT–II display

1. Actual current
2. Warning lamp
Check Condition
T Standard Value
AF
of pulley 1
pressure regu-
lator
current of pul-
ley 1 pressure
R
regulator
3. Actual current
of pulley 2 1. Warming up
pressure regu- 2. Drive for 15 minutes or
D
Dynamic data Pressure regulator condition

lator more so that the transmis-
4. C o m m a n d e d sion oil temperature be-
current of pul- comes 70-90 °C (158-194 °F).
ley 2 pressure
regulator
5. Actual current
of clutch pres-
sure regulator
current of
clutch pressure
regulator

CVT 23
T
AF
DOIMC023R11211
R
D

23 CVT
P0930: SHIFT LOCK SHORT CIRCUIT TO GROUND WCH023TSHOT11207
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.
T
AF
R
D
DOIQC023R11059

CVT 23
CONNECTOR: A-36 CONNECTOR: A-55x
T
AF
R
CONNECTOR: C-02 CONNECTOR: C-18

D

23 CVT
CONNECTOR: C–19 CONNECTOR: C-27
SHIFT LOCK SOLENOID STOP LAMP SWITCH
T
AF
R
D
Shift lock short cir- 1. High side off

cuit to Ground 2. Warning lamp

CVT 23
T
AF
R
D
DOIQC023R11100

23 CVT
P0931: SHIFT LOCK SHORT CIRCUIT TO BATTERY OR OPEN CIRCUIT WCH023TSHOT11208
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.
T
AF
R
D
DOIQC023R11060

CVT 23
T
AF
R

D

23 CVT
CONNECTOR: C–04 CONNECTOR: E-19
T
AF
R
SHIFT LOCK SOLENOID STOP LAMP SWITCH

D
Shift lock short cir- 1. Short circuit to battery
1. High side off 2. Open circuit
P0931 cuit to Battery or
open circuit

CVT 23
T
AF
R
D
DOIQC023R11101

23 CVT
P1768: BACKLIGHT SHORT CIRCUIT TO GROUND WCH023TSHOT11209
OPERATION
CVT-TCU detects malfunction using the backlight switch signal sent from the engine ECU.
T
AF
R
DOIQC023R11061
D

CVT 23
CONNECTOR: C-27
T
AF
DOINC023R11088
R
D
Backlight short cir- 1. High side off

cuit to Ground 2. Warning lamp

23 CVT
T
AF
R
D
DOIQC023R11102

CVT 23
P1769: BACKLIGHT SHORT CIRCUIT TO BATTERY OR OPEN CIRCUIT WCH023TSHOT11210
OPERATION
CVT-TCU detects malfunction using the backlight switch signal sent from the engine ECU.
T
AF
R
D
DOIQC023R11070

23 CVT
T
AF
R
CONNECTOR: C-27 CONNECTOR: C-31x

D

CVT 23
CONNECTOR: G-09 CONNECTOR: G-10
Backlight short cir- 1. Short circuit to battery
1. High side off 2. Open circuit
P1769 cuit to Battery or
T
open circuit
AF
R
D

23 CVT
T
AF
R
D
DOIQC023R11095

CVT 23
P0868: OPERATION READINESS TIME OUT WCH023TSHOT11211
OPERATION
Operation readiness is the end state of operation planning.
Operation readi- 1. High side off 2. Oil type problem
P0868 3. Oil pump defective
ness time out 2. Warning lamp
T
AF
R
D
DOIMC023R11169
P0811: CLUTCH (FORWARD OR REVERSE) SLIPPING WCH023TSHOT11212
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.

23 CVT
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
T
AF
R
D
DOIMC023R11166
P2787: CLUTCH TEMPERATURE TOO HIGH WCH023TSHOT11213
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.

CVT 23
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
T
AF
R
D
DOIMC023R11214

23 CVT
P0730: RATIO CONTROL FAULT WCH023TSHOT11214
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.
2. Oil type problem
1. High side off 3. Sensor or hydraulic unit de-
P0730 Ratio control fault
2. Warning lamp fective

Primary pulley Approximately same as tachomet-
speed er display
Engine at idling
Secondary pulley 2.43 X Primary pulley speed
Dynamic data
display
speed
pulley 2 pres-
T value
AF
Pulley 2 pressure operation
2. Measure pulley
2 pressure
R
D

CVT 23
T
AF
R
D
DOIMC023R11170

23 CVT
P1770: ENGINE SPEED TOO LOW WCH023TSHOT11215
OPERATION
The engine speed signal is transmitted from engine ECU to CVT-TCU via CAN communication line.
1. Idle speed controller problem
Engine speed too 2. Check engine problem
P1770 Warning lamp
low 3. Throttle body problem

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

CVT 23
P0727: HARDWIRED ENGINE SPEED UNPLAUSIBLE WCH023TSHOT11216
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.
T
AF
R
D
DOIQC023R11062

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

1. Warming up
Dynamic data
display
comes 70-90 °C (158-194 °F).
T
AF
R
D
DOIQC023R11097

CVT 23
P0219: POWERTRAIN SPEED OUT OF RANGE WCH023TSHOT11217
OPERATION
Indicates the vehicle has been operated in a manner which caused the engine speed to exceed a cal-
ibrated limit. The engine RPM is continuously monitored and evaluated by the engine ECU. The fault
code is set when the RPM exceeds the calibrated limit set within the engine ECU.
Powertrain speed 1. High side off
P0219 Fuel cut off problem
out of range 2. Warning lamp
1. Warming up
Dynamic data
display
comes 70-90 °C (158-194 °F).
T
AF
R
D
DOIMC023R11204
P0944: INSUFFICIENT CLAMPING FORCE (VSM) WCH023TSHOT11218
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).

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

CVT 23
T
AF
R
D
DOIMC023R11207

23 CVT
P1772: AT MODE SIGNAL ERROR WCH023TSHOT11219
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.
T
AF
R
D
DOIQC023R11063

CVT 23
T
AF
R
CONNECTOR: C-27 CONNECTOR: E-19

D

23 CVT
SAT SWITCH
DOIQC023R11103
AT mode signal er- 2. Open circuit
T
P1772 Warning lamp 3. Stepper motor switch mal-
ror
function
AF
Unknown / First Manual Gear /
Second Manual Gear / Third
Manual Gear / Fourth Manual
Gear / Fifth Manual Gear / Sixth
Manual Gear / R (reverse) / SAT;
Dynamic data
Lever position Ignition ON First Gear / SAT; Second Gear /
R
display
SAT;Third Gear / SAT; Fourth
Gear / SAT; Fifth Gear / SAT; Sixth
Gear / P (Park) / N (Neutral) / D
D
(Drive) / S (Sport) / L (Low) / Inval-

id (error)

CVT 23
T
AF
R
D
DOIQC023R11098
P080A: EOL CLUTCH ADAPTATION NOT FINISHED WCH023TSHOT11220
OPERATION
The clutches need an adaptation to compensate for tolerances after uploading new software in the
TCU, replacement of TCU or replacement of transmission. However, the fault code can come out when
clutch adaptation is not optimal or complete.
EOL clutch adapta-
P080A Warning lamp Clutch adaptation not complete
tion not finished

23 CVT

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
T
AF
R
D
DOIMC023R11209
P1774: END OF LINE (EOL) CLUTCH ADAPTATION ERROR WCH023TSHOT11221
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.
End of Line (EOL)
P1774 clutch adaptation Warning lamp Clutch adaptation error
error

CVT 23

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
T
AF
R
D
DOIMC023R11209

23 CVT
P0571: BRAKE SIGNAL ERROR WCH023TSHOT11222
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.
T
AF
R
D
DOIQC023R11064

CVT 23
T
AF
R
CONNECTOR: C-22 CONNECTOR:C-27

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

23 CVT

Dynamic data Brake status OFF/ON
Ignition ON
display Brake signal fault OK/FAIL
T
AF
R
D

CVT 23
T
AF
R
D
DOIQC023R11096

23 CVT
U0301: VEHICLE CONFIGURATION MISMATCH WCH023TSHOT11223
OPERATION
The fault code is sets when the configuration between two or more modules do not match.
Vehicle configura- 1. High side off Invalid combination of TCU
U0301
tion mismatch 2. Warning lamp hardware and software
T
AF
R
D
DOIMC023R11225

CVT 23
U0415: ABS FUNCTION ERROR WCH023TSHOT11224
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.
T
AF
R
D
DOIQC023R11065

23 CVT
T
AF
R
1. Increased clamping level 0
D
2. Substitute detection func-

U0415 ABS function error ABS system problem
tion of blocked and spin-
ning wheels
DOIMC023R11215

CVT 23
U0001: CAN BUS OFF WCH023TSHOT11225
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.
T
AF
R
D
DOIQC023R11066

23 CVT
T
AF
R
CONNECTOR: C-27 CONNECTOR: D-09

D

CVT 23
CONNECTOR: D-11
DOINC023R11098
1. Warning lamp
2. Emergency mode active
3.
4.
T
No manual mode
Increased clamping level 1
(highest)
AF
ning wheels
6. Activate internal driving
strategy
7. Substitute engine speed
8. Substitute engine torque 1. Short circuit between CAN
R
U0001 CAN bus off 9. Substitute engine cooling high and CAN low
water temperature 2. TCU malfunction
10. Brake signal on
D
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

23 CVT
T
AF
DOIQC023R11107
R
U0121: CAN ABS COMMUNICATION FAILED WCH023TSHOT11226
OPERATION
D
ECU receives the data (such as ABS sensor signal, ABS operation signal) via the CAN bus lines. If it
cannot receive such data, it interrupts the system.
ning wheels
3. Substitute front left wheel 1. ABS controller failure
CAN ABS commnu- speed 2. CAN connection problem
U0121
cation failed 4. Substitute front right wheel from ABS controller
speed
speed
speed

CVT 23
DOIMC023R11217
U0100: CAN ECU COMMUNICATION FAILED WCH023TSHOT11227
OPERATION
ECU receives the data (such as engine controller signal, engine operation signal) via the CAN bus lines.
If it cannot receive such data, it interrupts the system.
1.
T
Reaction from TCU
Warning lamp
Probable cause
AF
3. No manual mode
5. Activate internal driving
strategy 1. Engine controller failure
CAN ECU commnu- 2. CAN connection problem
U0100 6. Substitute engine speed
cation failed from engine controller
7. Substitute engine torque
R
8. Substitute engine cooling

water temperature
9. Accelerator pedal value
D
fixed
10. Stop transmitting on CAN
DOIMC023R11218

23 CVT
U1012: CAN ENGINE SPEED SIGNAL ERROR WCH023TSHOT11228
OPERATION
ECU receives the data (such as motor controller signal, motor speed sensor signal) via the CAN bus
lines. If it cannot receive such data, it interrupts the system.
CAN engine speed 1. Warning lamp 1. Motor speed sensor defective
U1012 2. Sensor wiring problem
signal error 2. Substitute engine speed

1. Warming up
Dynamic data more so that the transmis-
Engine speed ± 850 rpm (Idling)
display sion oil temperature be-
comes 70 - 90 °C (158 - 194
°F)
T
AF
R
DOIMC023R11219
U1013: CAN ACCELERATOR PEDAL SIGNAL ERROR WCH023TSHOT11229

D
OPERATION
ECU receives the data (such as EMS controller signal, accelerator pedal sensor signal) via the CAN bus
lines. If it cannot receive such data, it interrupts the system.
1. Warning lamp 1. Accelerator pedal sensor de-
CAN accelerator fective
U1013 2. Accelerator pedal value
pedal signal error 2. Sensor wiring problem
fixed

CVT 23
DOIMC023R11220
U1014: CAN ENGINE TORQUE SIGNAL ERROR WCH023TSHOT11230
OPERATION
ECU receives the data (such as EMS controller signal) via the CAN bus lines. If it cannot receive such
data, it interrupts the system.
1.
T
Reaction from TCU
Warning lamp
Probable cause
AF
CAN engine 3. No manual mode
U1014 EMS controller problem
torque signal error 4. Activate internal driving
strategy
5. Substitute engine torque
R
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)
D
DOIMC023R11221

23 CVT
U1016: CAN WHEEL SPEED ERROR — FRONT LEFT WCH023TSHOT11231
OPERATION
ECU receives the data (such as ABS controller signal, wheel speed sensor signal) via the CAN bus lines.
T
AF
R
D
DOIQC023R11067

CVT 23
T
AF
R

D

23 CVT
CONNECTOR: D-09 CONNECTOR: D-11
U1016
CAN wheel speed
sensor — front left ning wheels
T
tion of blocked and spin- 1. Wheel speed sensor defective
3. Substitute front left wheel

AF
speed
R
D
DOIMC023R11222

CVT 23
U1017: CAN WHEEL SPEED ERROR — FRONT RIGHT WCH023TSHOT11232
OPERATION
T
AF
R
D
DOIQC023R11067

23 CVT
T
AF
R

D

CVT 23
CAN wheel speed
U1017 sensor — front
right
ning wheels
T
3. Substitute front right wheel

AF
speed
R
D
DOIMC023R11222

23 CVT
U1018: CAN WHEEL SPEED ERROR — REAR LEFT WCH023TSHOT11233
OPERATION
T
AF
R
D
DOIQC023R11067

CVT 23
T
AF
R

D

23 CVT
U1018
CAN wheel speed
sensor — rear left ning wheels
T

AF
speed
R
D
DOIMC023R11222

CVT 23
U1019: CAN WHEEL SPEED ERROR — REAR RIGHT WCH023TSHOT11234
OPERATION
T
AF
R
D
DOIQC023R11067

23 CVT
T
AF
R

D

CVT 23
CAN wheel speed
U1019 sensor — rear
right
ning wheels
T

AF
speed
R
D
DOIMC023R11222
TROUBLE SYMPTOM WCH023TSHOT11235
TROUBLE SYMPTOM CHART

CAUTION:
During diagnosis, a diagnosis code associated with other system may be set when the ignition
switch is turned on with connector(s) disconnected. On completion, confirm all systems for diagnosis
code(s). If diagnosis code(s) are set, erase them all.
Trouble symptom Inspection procedure number Reference page
Communication with the PADT-II is not possible 1 23/255
(CVT-TCU cannot be turned ON)
Vehicle creeps in the N range 2 23/257
Shock is experienced during N to D and/or N to 3 23/257
R shifting operation

23 CVT
Trouble symptom Inspection procedure number Reference page

Poor acceleration or incomplete shifting opera- 4 23/258
tion
Gears cannot be changed in SAT (Stepped 5 23/260
Automatic Transmission) mode
Abnormal gear indicator at meter combination 6 WCH023TSHOT12005
display
T
AF
R
D

CVT 23
SYMPTOM PROCEDURES / 255
SYMPTOM PROCEDURES WCH023TSHOT11236
Inspection Procedure 1: Communication with the PADT-II is not Possible (CVT-TCU

cannot be turned ON).
T
AF
R
D
DOIQC023R11108
SYMPTOMS PROBABLE CAUSES

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

23 CVT
/ 256 SYMPTOM PROCEDURES
DIAGNOSIS PROCEDURE
T
AF
R
D
DOIQC023R11068

CVT 23
Inspection Procedure 2: Vehicle Creeps in the N Range. WCH023TSHOT11237

Engine torque is transferred to the drive shaft • Malfunction of the drive mode sensor.
in the N range, and the vehicle consequently • Malfunction of CVT assembly.
moves forward or rearward. • Damaged wiring harness and connectors.
• Malfunction of CVT-ECU.
DIAGNOSIS PROCEDURE
T
AF
R
D
DOINC023R11186
Inspection Procedure 3: Shock is experienced during N to D and/or N to R shifting

operation. WCH023TSHOT11238

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

23 CVT
DIAGNOSIS PROCEDURE
T
AF
R
DOINC023R11187
Inspection Procedure 4: Poor Acceleration or Incomplete Shifting Operation

WCH023TSHOT11239
D

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

CVT 23
DIAGNOSIS PROCEDURE
T
AF
R
DOINC023R11188
D

23 CVT
Inspection Procedure 5: Gears cannot be Changed in SAT Mode. WCH023TSHOT11240
T
AF
R
DOIQC023R11109

Gears cannot be changed even when the SAT • Damaged wiring harness and connectors
D
mode button is switch. • SAT mode button malfunction

• Malfunction of CVT-ECU

CVT 23
DATA LIST / 261
DIAGNOSIS PROCEDURE
T
AF
R
DOIQC023R11069
DATA LIST WCH023TSHOT11241

D

Item Standard Measure-
PADT-II display Check condition Remarks
no value ment unit
Engine runs at idle,
A/C OFF
1 Engine speed ± 850 rpm rpm Engine speeds at idle
Engine runs at idle,
A/C ON
-10 kgm (-100
Engine torque - Engine torque data
2 Vehicle being driven Nm, -72.33 Nm
CAN status; data by ECU
ft.lbs)
and data request by
25 kgm (250 TCU (approximately
Engine torque -
3 Vehicle being driven Nm, 180.82 Nm similar value)
TCU
ft.lbs)
Ignition ON 8.63%
4 Throttle position % TPS Throttle position
Engine runs at idle 4.31%

23 CVT
/ 262 DATA LIST
89 °C (192.2 °F)
Engine coolant Engine coolant tem-
5 Engine runs at idle ~ 92 °C (197.6 °C
temp perature
°F)?
< 120 °C (248 Transmission coolant
6 Oil temperature Engine runs at idle °C
°F) temperature
Vehicle speed - out- 0 km/h (0 Value increases as
7 Ignition ON km/h
put speed mph) vehicle moves
Vehicle speed - 0 km/h (0 Value increases as
8 Ignition ON km/h
TCU mph) vehicle moves
0 km/h (0 Determine slipping
Average speed of
9 Vehicle being driven mph)~top km/h wheel between front
none driven wheels
speed km/h and rear
Approximately similar
Primary pulley
10 Vehicle being driven 0~7000 rpm rpm as the tachometer dis-
speed
play
Idling ratio of 2.43 X
Secondary pulley
11 Vehicle being driven — rpm Primary pulley speed
speed
value
T
Secondary pulley
12 Output speed Vehicle being driven — rpm
speed value X 5.76
13 Gear ratio Vehicle being driven 0.43~2.43 — Gear ratio operation
AF
value (Approximately
14 Target ratio Vehicle being driven 0.43~2.43 — similar value)
Timing measurement
for gear ratio to
15 Ratio gradient Vehicle being driven — 1/s
achieve target ratio
value
R
Gear shift position Clutch open when

16 Clutch slip (+ value) < 500 rpm
at D/R value > 500
Invalid / Open / Filling
/ Applied / Creeping /
D
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
Manual Gear / Sixth
Manual Gear / R (re-
verse) / SAT; First Gear
18 Lever position — — —
/ SAT; Second Gear /
SAT;Third Gear / SAT;
Fourth Gear / SAT;
Fifth Gear / SAT; Sixth
Gear / P (Park) / N
(Neutral) / D (Drive) /
S (Sport) / L (Low) / In-
valid (error)

CVT 23
DATA LIST / 263
Check the fault code

19 Number of DTC Ignition ON — —
if the value > 1
MIL physical output
20 MIL status Ignition ON OFF/ON —
indication
Brake pedal status
21 Brake status Ignition ON OFF/ON —
(Brake light switch)
22 Brake fault status Ignition ON OK/FAIL — Brake fault status
23 Shift lock Ignition ON OFF/ON — Shift lock status
Commanded clutch
24 Vehicle being driven 0–10 bar Clutch pressure opera-
pressure
tion (Approximately
Expected clutch similar value)
25 Vehicle being driven 0–10 bar
pressure
Commanded pulley
26 Vehicle being driven 0–50 bar Pulley 2 pressure oper-
2 pressure
ation (Approximately
Measured pulley 2 similar value)
27 Vehicle being driven 0–50 bar
pressure
Commanded cur-
28 rent of Pulley 1 Vehicle being driven 0–1000 mA Pulley 1 pressure regu-
29
Pressure Regulator
Actual current of
Pulley 1 Pressure Vehicle being driven
T 0–1000 mA
lator operation (Ap-
proximately similar
value)
AF
Regulator
Commanded cur-
30 rent of Pulley 2 Vehicle being driven 0–1000 mA Pulley 2 pressure regu-
Pressure Regulator lator operation (Ap-
Actual current of proximately similar
31 Pulley 2 Pressure Vehicle being driven 0–1000 mA value)
R
Regulator
Commanded cur-
32 rent of Clutch Pres- Vehicle being driven 0–1000 mA Clutch pressure regu-
D
sure Regulator lator operation (Ap-

Actual current of proximately similar
33 Clutch Pressure Vehicle being driven 0–1000 mA value)
Regulator
Ignition ON 11.6 V ~ 12.0 V
34 Battery voltage V Battery voltage level
Engine runs at idle 13.5 V
High side voltage 0 V
35 High side voltage Ignition ON >3.4 V V
when fault occur
Voltage during igni-
36 Ignition voltage Ignition ON 11.6 V ~ 12.0 V V
tion
Oil pressure sensor in-
37 5V sensor voltage Ignition ON 5.0 V V
put voltage
DMS and primary &
38 8.4V sensor voltage Ignition ON 8.4 V V secondary speed
sensor input voltage
39 Mileage Ignition ON — km Driven distance

23 CVT
/ 264 DATA LIST
No Error / Unstable
Engine torque / Air-
cond ON / Pressure
EOL Clutch Adapta-
40 Ignition ON — — too high / Engine
tion Error
speed too low / En-
gine speed too high /
Too many abortions
T
AF
R
D

CVT 23
CHECK AT CVT TCU TERMINALS / 265
CHECK AT CVT TCU TERMINALS WCH023TSHOT11242
TERMINAL VOLTAGE
1. Connect a needle-nosed wire probe (Test harness: MB991223 or paper clip) to a voltmeter probe.
2. Insert the neddle-nosed wire probe into each of the CVT-TCU connector terminals from the side,
and measure the voltage while referring to the check chart.
NOTE
(1) Make sure the voltage measurement with the CVT-TCU connected.
(2) You may find it convenient to pull out the CVT-TCU in order to make it easier to reach con-
nector terminals.
3. If voltmeter shows any unordinary value from standard value, check the corresponding sensor,
actuator or related electrical wiring. Then repair or replace the corresponding.
4. After repair or replace, recheck with the voltmeter to reconfirm that the problem has been solved.
CAUTION
vehicle wiring, sensor, CVT-TCU or all of them. Be careful to prevent this!
T
AF
R
D
DOINC023R11191

23 CVT
/ 266 CHECK AT CVT TCU TERMINALS
Ter-
minal Description Check item Standard value
No.
1 Permanent supply
Always System voltage
2 (12V)
3
Ground Always System voltage
4
VHSD1 (High side
5 Always System voltage
actuator supply)
Ignition supply
6 Ignition switch: ON System voltage
(wake up)
8 CAN Low 1 — Approximately 1.908 V ± 0.2 V
9 CAN High 1 — Approximately 3.136 V ± 0.2 V
30 Speed & Drive
77 mode sensor sup- Ignition switch: ON 8.4 V
78 ply (8.4V)
32 Oil pressure sensor
Ignition switch: ON 4.5 V ± 0.5 V
74
33
supply (5V)
Drive mode sensor
ground
Always
T 0.55 V ± 0.5 V
AF
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
R
Transmission oil
temperature
41
D
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
59 Sport_Manual
Primary pulley
TCU discon-
61 speed signal Pin 77 and pin 61 5.3 MΩ
nect
(N_Prim)
Transmission out-
TCU discon-
63 put speed signal Pin 77 and pin 63 5.3 MΩ
nect
(N_AB)
71 Back light relay Ignition switch: ON System voltage

CVT 23
CHECK AT CVT TCU TERMINALS / 267
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
80 Tip_Down
81 Tip_Up
Engine speed sig-
87 — — — —
nal (N_MOT)
Ignition
89 EDS3 Pin 8 and pin 89 2.5 V ± 0.5 V 5.7 Ω
switch: ON
Ignition
T
switch: ON
Ignition
switch: ON
AF
Ignition P/N 0V
92 Start lock
switch: ON Others 12 V
R
D

23 CVT
/ 268 CHECK AT CVT CONNECTOR
CHECK AT CVT CONNECTOR WCH023TSHOT11243
TERMINAL ARRANGEMENT
TERMINAL ARRANGEMENT
T
AF
R
DOINC023R11190
D
Pin no Signal
1 Supply valves (VHS)
2 Primary pressure regulator (EDS1)
3 Secondary pressure regulator (EDS2)
4 Clutch pressure regulator (EDS3)
5 Oil temperature sensor
6 Drive mode sensor Ground (DMS_GND)
7 Ground
8 Supply (5.0 V)
9 Supply (8.4 V)
10 Secondary pressure sensor
11 Secondary speed sensor
12 Primary speed sensor
13 Drive mode sensor A (DMS_A)
14 Drive mode sensor B (DMS_B)

CVT 23
CHECK AT CVT CONNECTOR / 269
Pin no Signal
15 Drive mode sensor C (DMS_C)
16 Drive mode sensor D (DMS_D)
T
AF
R
D

23 CVT
/ 270 CHECK AT CVT CONNECTOR
In most cases the error codes from the TCU will indicate if there is something wrong with one of the
electronic components inside the transmission. The following resistor measurements can be performed
to check if the electronic components are faulty or not. All measurements indicated here are performed
on the main harness connector of the transmission.
Item
Item Pin no. Resistance value
no.
20 °C (68 °F) 942 Ω
1 Oil temperature sensor Measure between pin 5 and pin 7
40 °C (104 °F) 1121 Ω
2 Primary speed sensor Measure between pin 9 and pin 12 24.3 MΩ
3 Secondary speed sensor Measure between pin 9 and pin 11 24.3 MΩ
Primary pressure regulator
6 Measure between pin 1 and pin 3 5.2 Ω
(EDS1)
Secondary pressure regulat-
or (EDS2)
Clutch pressure regulator
(EDS3)
4 Secondary pressure sensor Measure between pin 7 and pin 10 44.3 kΩ
DRIVE MODE SENSOR
T
Check the internal resistance between the different DMS pins.
AF
Supply (8.4 V) DMS_A DMS_B DMS_C DMS_D
Supply (8.4 V) — 17.2 MΩ 17.2 MΩ 17.2 MΩ 17.2 MΩ
DMS_A 17.2 MΩ — 9.0 kΩ 9.0 kΩ 9.0 kΩ
DMS_B 17.2 MΩ 9.0 kΩ — 9.0 kΩ 9.0 kΩ
DMS_C 17.2 MΩ 9.0 kΩ 9.0 kΩ — 9.0 kΩ
DMS_D 17.2 MΩ 9.0 kΩ 9.0 kΩ 9.0 kΩ —
R
DMS_GND — 4.5 kΩ 4.5 kΩ 4.5 kΩ 4.5 kΩ

NOTE
Ranges of resistor values can differ in function of the accuracy of the measuring equipment.
D

WHEEL AND TYRE 31
Content /1
31 WHEEL AND TYRE

INFORMATION ...................................................................... 31/2
SPECIFICATIONS ....................................................................... 31/2

SERVICE SPECIFICATIONS ......................................................... 31/2

SYMPTOMS ........................................................................... 31/3

TYRE INFLATION PRESSURE CHECK .............................................. 31/4
TYRE WEAR CHECK ................................................................. 31/4
WHEEL RUNOUT CHECK ........................................................... 31/5
FRONT WHEEL AND REAR WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31/5
SPARE TYRE AND JACK .............................................................. 31/7

JACK POSITION ...................................................................... 31/8
T
AF
R
D

31 WHEEL AND TYRE
INFORMATION
The wheels and tyres of the following specification have been established
Items Base-Line Med-Line Hi-Line

Wheel
Type Steel Aluminium alloy
Size 16 x 6.5 JJ 16 x 6.5 JJ
Amount of wheel offset 46 mm (1.81 in) 46 mm (1.81 in)
Pitch circle diameter 114.3 mm (4.5 in) 114.3 mm (4.5 in)
(P.C.D.)
Tyre
Size 205/55R16 90H
Spare wheel
Type Steel rim
Size 4TX16
Tyre
Size
SPECIFICATIONS
T T135/70D16
AF
WCH031SPECS12001
Specification
Items
205/55R16
Tyre inflation pressure (Standard)
R
Tyre Front 220 kPa (31.3 psi, 66.41 in.Hg)

Tyre Rear 210 kPa (29.87 psi, 63.39 in.Hg)
Tyre spare 400 kPa (56.9 psi, 120.75 in.Hg)
D
Tread depth of Tyre (Limit) 1.6 mm (0.063 in)

Wheel runout (Limit)
Radial runout (Aluminium 1.0 mm (0.039 in) or less
wheel)
Lateral runout (Aluminium 1.0 mm (0.039 in) or less
wheel)

WHEEL AND TYRE 31
TROUBLESHOOTING /3
SYMPTOMS
Symptoms Probable causes Remedies Reference pages
DOIIC031R9012 DOIIC031R9001
Rapid wear at shoulders Under-inflation or lack of
rotation
Adjust the tyre Refer to Tyre Inflation
pressure Pressure Check on page
WCH031SPECS022
DOIIC031R9011
Rapid wear at center Over-inflation or lack of
rotation
T
DOIIC031R9002
AF
Under-inflation
R
DOIIC031R9010
Cracked treads
D
Refer to GROUP 33A

Front Suspension - Ser-
Inspect the camber
vice Adjustment Proced-
ures
Wear on one side Excessive camber
Refer to GROUP 33A

Front Suspension - Ser-
Adjust the toe-in
vice Adjustment Proced-
ures
Feather edge Incorrect toe-in

31 WHEEL AND TYRE
Symptoms Probable causes Remedies Reference pages

—
Wheel balancing
Bald spots Unbalanced wheel
Rotate the tyres Refer to GROUP 33A

Lack of rotation of tyre or
and inspect the Front Suspension - Ser-
worn or out-of-alignment
front suspension vice Adjustment Proced-
suspension
alignment ures
DOIIC031R9006
Scalloped wear
T TYRE INFLATION PRESSURE CHECK

Check the inflation pressure of the tyres. If they
AF
are not within the standard value, make the ne-
cessary adjustment.
Tyre pressure label is located at at center pillar
RH (driver side) as shown in the illustration.
NOTE :
Recommended pressures are shown on the tyre
R
pressure label.
DOIQC031R12001
TYRE WEAR CHECK

D
Measure the tread depth of tyres.

Limit:
1.6 mm (0.063 in)
If the remaining tread depth is less the limit, re-

place the tyre.
Symbols Descriptions
1 Tread wear indicator positions
DOIAW010R3012
2 Tread wear indicator
NOTE
When the tread depth of the tyres is reduced to
1.6 mm (0.063 in) or less, wear indicators will
appear.

WHEEL AND TYRE 31
WHEEL RUNOUT CHECK

Jack up the vehicle so that the wheels are clear
of the floor.
While slowly turning the wheel, measure the
wheel runout with a dial indicator.
A Radial
B Lateral
Limit:
Items Limits
DOIIC031R9013
Radial runout (alumini- 1.0 mm (0.039 in)
um wheel)
Lateral runout (alumini- 1.0 mm (0.039 in)
um wheel)
If the wheel runout exceeds the limit, replace

the wheel.
T INSTALLATION SERVICE POINT

FRONT WHEEL AND REAR WHEEL INSTALLATION
AF
1. Check that the mating surface on the brake
disc or brake drum and wheel rims are clean.
2. Install the wheel to the vehicle properly.
3. Pre-screw wheel nuts (by hand) until the
tapered part of the wheel nuts make light
contact with the seats of the wheel holes.
R
A Nut (For steel wheel)
B Nut (For alloy wheel)
D
CAUTION:
Never apply oil during tightening the wheel
bolts or nuts because it will cause overtight-
en.
DOINC031R08003

31 WHEEL AND TYRE
4. Tighten the nuts lightly and then tighten the

nuts crosswise to the specified torque.
Tightening torque:
9.0 ~ 11.0 Kgf.m
CAUTION:
(1) Crosswise tightening and correct tighten-
ing torques are important to avoid
stresses in the wheel and brake disc or
drum.
(2) Never use extra force by your foot to the
wheel nut wrench or a pipe extension
DOINC031R08001 as you can overtighten the nut.
T
AF
R
D

WHEEL AND TYRE 31
SPARE TYRE AND JACK /7
SPARE TYRE AND JACK WCH031SASSY12001
T
AF
R
DOIQC031R12002
D
Removal steps
1. Velcro Strap
2. Jack Assy
3. Spare Tyre Retainer
4. Spare Tyre
T1 : >0.49 kgm (4.9 Nm, 3.54 ft.lbs)

31 WHEEL AND TYRE
/8 SPARE TYRE AND JACK
JACK POSITION
T
AF
R
DOIQC031R12003
Note:
1. Production installation is as per condition A
D
2. Temporary storage of standard tyre is as per condition B (when spare tyre is in use)
3. Pull and secure strap to tighten jack and tool set

POWER PLANT MOUNT 32
Content /1
32 POWER PLANT MOUNT

CONSTRUCTION DIAGRAM ....................................................... 32/2
ENGINE MOUNTING ................................................................. 32/3

INSTALLATION SERVICE POINT .................................................. 32/5
TRANSMISSION MOUNTING ........................................................ 32/6

FRONT AND REAR ROLL MOUNTING BRACKET ASSY ........................ 32/10

INSTALLATION SERVICE POINT .................................................. 32/12
T
FRONT SUB FRAME ................................................................... 32/13
AF
R
D

The engine-transmission mount is of an inertial axis supporting type whose excellent features have
already been proven in many PROTON vehicles . The inertial axis supporting type mount supports the
front upper part of the engine at front and the rear upper part of the transmission at the rear . This
arrangement effectively suppresses the engine vibration.
T
AF
R
D
DOIQC032R12011
Symbol Description
A Engine mounting bracket assy
B Transmission mounting bracket assy
C Rear roll mounting bracket assy
D Sub frame
E Front roll mounting bracket assy

ENGINE MOUNTING /3
ENGINE MOUNTING WCH032SASSY11010
T
AF
R
DOIQC032R12006
D
• 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
5. Engine mount insulator mounting bolt
6. Engine mount bracket
7. Engine mount stopper
CAUTION
Mounting locations marked by * should be provisionally tightened, and then fully tightened when
T1 : 0.8~1.4 kgm (8~14 Nm, 5.79~10.13 ft.lbs)
T3* : 10.0 kgm (100 Nm, 72.33 ft.lbs) ± 1.0 kgm (10 Nm, 7.23 ft.lbs)

/4 ENGINE MOUNTING
ENGINE MOUNTING BRACKET REMOVAL

1. Remove the lower cover. (Refer Group 051
— Lower Cover)
DOIQC032R11002
2. Use the garage jack to support the engine.
T
AF
DOIQC032R11003
3. Remove the power steering pressure hose

clamp mounting bolt.
R
Symbol Description
Power steering pressure hose
A
clamp
D
DOIQC032R11005
4. Remove the air cond section flexible bracket

mounting in order to make it easier to re-
move engine mounting bracket.
Symbol Description
Air cond section flexible
A
bracket
DOIQC032R11004

ENGINE MOUNTING /5
5. Remove the engine mounting nut (2 pieces)

and bolt (1 piece).
Symbol Description
A Nut
B Bolt
DOIQC032R11006
6. Remove the engine insulator mounting bolt.
T
AF
DOIQC032R11007
7. Remove the engine mounting bracket assy.

R
D
DOIQC032R11008

ENGINE MOUNT STOPPER INSTALLATION
Install the engine mounting stopper so that the
arrow is pointing up as shown in the illustration.
ENGINE MOUNTING BRACKET INSTALLATION

back engine mounting bracket.
DOIQC032R11009

/6 TRANSMISSION MOUNTING
TRANSMISSION MOUNTING WCH032SASSY11011
T
AF
R
DOIQC032R12007
D
Non-reusable parts
• Air cleaner assembly removal and installation (Refer to WCH015SASSY11005).
• Charge air duct assembly removal and installation (Refer to WCH015SASSY11005).
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)

TRANSMISSION MOUNTING /7
TRANSMISSION MOUNTING BRACKET

REMOVAL
• Support the transmission assy by using garage
jack.
DOIQC032R11003
• Remove air cleaner (Refer Group 15 — Intake

and Exhaust).
T
AF
DOIQC032R12001
• Remove charge air duct assy (Refer Group 15

— Intake and Exhaust).
R
D
DOIQC032R12002
CVT Transmission:
1. Remove the transmission insulator mounting
bolt.
DOIQC032R12003

/8 TRANSMISSION MOUNTING
2. Remove the transmission mounting nut (2

pieces) and bolt (1 piece).
Symbol Description
A Bolt
B Nut
DOIQC032R12004

assy.
T
AF
DOIQC032R12005
Manual Transmission:
1. Remove the transmission insulator mounting
bolt.
R
D
DOIQC032R12013
2. Remove the transmission mounting nut (4

pieces).
Symbol Description
A Nut
DOIQC032R12014

TRANSMISSION MOUNTING /9

assy.
DOIQC032R12015

INSTALLATION
Install the transmission mounting stopper so that
the arrow (UP) points in the direction as shown
T
AF
DOINC032R11014
TRANSMISSION MOUNTING BRACKET

INSTALLATION
R

back transmission mounting bracket.
D
DOIQC032R12016

/ 10 FRONT AND REAR ROLL MOUNTING BRACKET ASSY
FRONT AND REAR ROLL MOUNTING BRACKET ASSY WCH032SASSY11012
T
AF
R
DOIQC032R12008
D

• Front sub-frame removal and installation (Refer to Pub. No. RDCE-09FZ6Y010–00, GROUP 032–Front
sub-frame).
• Remove the under cover
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)
T3 : 3.9~4.2 kgm (39~42 Nm, 28.21~30.38 ft.lbs)

FRONT AND REAR ROLL MOUNTING BRACKET ASSY / 11
FRONT ROLL MOUNTING BRACKET ASSY

REMOVAL
1. Remove the front roll mounting bracket bolts
(2 pieces).
Symbol Description
A Bolt
DOIQC032R11028
2. Remove the front roll insulator mounting

bracket bolt and nut.
T
AF
DOIQC032R11029
3. Remove the front roll insulator mounting

bracket assy.
R
D
DOIQC032R11030
REAR ROLL MOUNTING BRACKET ASSY

REMOVAL
1. Remove the rear roll insulator mounting
bracket bolt and nut.
Symbol Description
A Nut
DOIQC032R11032

/ 12 FRONT AND REAR ROLL MOUNTING BRACKET ASSY
2. Remove the rear roll mounting bracket bolt

and nut.
Symbol Description
A Nut
DOIQC032R11033
3. Remove the rear roll mounting bracket lower

nut and remove the rear roll mounting assy.
T
AF
DOIQC032R11034

FRONT ROLL MOUNTING BRACKET ASSY
R
INSTALLATION
When installing the front roll mounting bracket
assy, the marking (A) must be positioned at the
D
front side as shown in the illustration.
DOIQC032R11031

FRONT SUB FRAME / 13
FRONT SUB FRAME WCH032SASSY11013
T
AF
R
DOIQC032R12009
D
Non-reusable parts
• Align tyre and steering on straight position
• Front tyre RH and LH removal
• Undercover removal
NOTE:
In order to remove the front sub frame, support the power steering assy securely at safe location.
Removal steps 7. Rear roll mounting insulator bolt
1. Under cover 8. Front exhaust pipe
2. Front sub frame (with stabilizer bar) 9. Steering linkage bolt (RHS)
3. Stabilizer link lower connection 10. Plate clamp steering linkage (LHS)
4. Lower arm ball joint assy bolt 11. Supporter sub frame mounting LH
5. Tube cooler power stering bolt 12. Supporter sub frame mounting RH
6. Front roll mounting insulator bolt
T1 : 4.5 ± 0.5 kgf.m T5 : 5.0 ~ 6.0 kgf.m
T2 : 8.0 ~ 10.0 kgf.m T6 : 11.0 ~ 14.0 kgf.m
T3 : 1.0 ± 0.2 kgf.m T7 : 4.0 ~ 5.0 kgf.m
T4 : 5.9 ~ 6.4 kgf.m

/ 14 FRONT SUB FRAME

1. Remove the tyre RH and LH side.
DOIQC032R11027
2. Lift up the vehicle and remove the lower

cover. (Refer GROUP 051 — Lower Cover)
T
AF
DOIQC032R11002
3. Remove the cable assy CVT. (Refer GROUP

023 — CVT)
R
D
DOIQC032R11010
4. Remove the stabilizer lower link connection.
DOIQC032R11011

5. Remove the tie rod end ball joint by using

special tool (MB991113). (Refer GROUP 37A
— Steering)
Symbol Description
DOIQC032R11012
6. Remove the lower arm ball joint assy bolt

and nut.
T
AF
DOIQC032R11013
7. Pull down the lower arm assembly as shown

R
D
DOIQC032R11014
8. Remove the tube cooler power steering bolt.
DOIQC032R11015

9. Support the steering linkage assembly with

a wire as shown in illustration.
DOIQC032R11016
10. Remove the power steering linkage mount-

ing bolt (RH side) and the plate clamp steer-
ing linkage (LH side).
T
AF
DOIQC032R11017
11. Remove the front roll mounting insulator

bolt.
R
D
DOIQC032R11018
12. Remove the front exhaust pipe.
DOIQC032R11019

13. Remove the rubber hanger connecting the

exhaust pipe and the underbody.
DOIQC032R11023
14. Remove the oxygen sensor.
T
AF
DOIQC032R11020
15. Remove the rear roll mounting insulator bolt.

R
D
DOIQC032R11021
16. Remove the 2 pieces bolt supporter sub

frame mounting (RHS & LHS).
Symbol Description
A Bolt
DOIQC032R11022

17. Loosen the sub frame mounting bolt front

RH & LH.
CAUTION:
Do not too loosen the sub frame mounting
bolt (loosen quarterly of the bolt only).
DOIQC032R11024
18. Loosen the sub frame mounting bolt rear RH

& LH.
CAUTION:
Do not too loosen the sub frame mounting
bolt (loosen quarterly of the bolt only).
T
AF
DOIQC032R11025
19. Lift down the vehicle and then remove the

sub frame mounting bolts (4 pieces).
R
D
DOIQC032R11026
20. Move out the sub frame from the vehicle.
DOINC032R09047

FRONT SUSPENSION 33A
Content /1
33A FRONT SUSPENSION

SPECIFICATIONS ....................................................................... 33A/2
GENERAL SPECIFICATIONS ........................................................ 33A/2
SERVICE SPECIFICATIONS ......................................................... 33A/2
SPECIAL TOOLS ....................................................................... 33A/2

TOOLS ................................................................................ 33A/2

SYMPTOM ............................................................................ 33A/3

FRONT WHEEL ALIGNMENT CHECK AND ADJUSTMENT .................... 33A/4
TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33A/4
STEERING ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33A/4
CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33A/4
STRUT ASSEMBLY .................................................................... 33A/6

REMOVAL AND INSTALLATION .................................................. 33A/6
REMOVAL SERVICE POINT ........................................................ 33A/7
INSPECTION .........................................................................
INSTALLATION SERVICE POINT ..................................................
DISASSEMBLY AND REASSEMBLY ................................................
T 33A/7
33A/8
33A/9
AF
DISASSEMBLY SERVICE POINT .................................................... 33A/10
INSPECTION ......................................................................... 33A/11
STRUT CHECK FOR GAS LEAK AND JERKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33A/11
REASSEMBLY SERVICE POINT ..................................................... 33A/12
LOWER ARM ........................................................................... 33A/14

R
REMOVAL SERVICE POINT ........................................................ 33A/15

INSPECTION ......................................................................... 33A/16
BALL JOINT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33A/16
LOWER ARM ASSEMBLY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33A/16
D
INSTALLATION SERVICE POINT .................................................. 33A/16
STABILIZER BAR ....................................................................... 33A/18

INSPECTION .......................................................................... 33A/19
STABILIZER LINK BALL JOINT CONTINUOUS ROTATING TORQUE INSPECTION . . . . . . . . . 33A/19
STABILIZER LINK BALL JOINT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33A/20

/2 SPECIFICATIONS
SPECIFICATIONS WCH33ASPECS12001
Suspension system McPherson strut with coil spring and compression rod type
Coil Wire dia x O.D. x free 12.2 mm (0.48 in) x 142.0 mm (5.59 in) x 378 mm (14.88 in)
spring length
Identification colour Yellow
Load rate 22 ± 0.66 N/mm
Front Type Gas cylindrical double acting type
strut
Stroke 155.6 mm (6.13 in)
Damping force [at 0.3
m/sec]
Expansion 1239 ± 181.0 N
Contraction 412 ± 86 N
Toe-in LH/RH
Camber LH/RH*
Items
T
Value
- 0.05°
- 0.4°
Allowance
± 0.05°
± 0.5°
AF
Caster LH/RH* 3.0° ± 1.0°
Steering Inner wheel + 0.5°
angle 32.7°
– 1.0°
Outer wheel + 0.5°
38.9°
– 1.0°
R
* : Allowed difference between left and right angle = 30'

D
TOOLS
Tools Numbers Names Uses
A:MB991237 A: Spring com- Compression of the front coil
B:MB991238 pressor body spring
B: Arm set
DOIIC33AR9003

TROUBLESHOOTING /3
Tools Numbers Names Uses

MB990326 Preload socket
Measurement of the ball joint

DOIIC33AR9006
rotation starting torque and
MB990685 Torque wrench continuous rotating torque.
DOIIC034R9004
MB990767 End yoke holder Holding the strut mounting assy
DOIIC027R9002
T
AF
TROUBLESHOOTING WCH33ATSHOT12001
SYMPTOM
Steering wheel vibrates or pulls Wheel alignment out of specification Inspect, adjust
R
to one side Coil spring or shock absorber malfunc- Replace

tion
Ball joint malfunction Replace
D
Imbalance wheel or worn tyres Refer to Group 31 –

Wheel & Tyre
Steering wheel is heavy Ball joint malfunction Replace
Excessive vehicle rolling Broken or deteriorated coil spring shock Replace
or absorber malfunction
Poor riding Broken or deteriorated coil spring shock Replace
Over inflation pressure of tyre Refer to Group 31 –
Wheel & Tyre
Inclination of vehicle Broken or deteriorated coil spring / Replace
shock absorber
Noise Lack of lubrication Replace
Looseness and wear Retighten subframe and
top mount or replace
Broken or deteriorated coil spring shock Replace

FRONT WHEEL ALIGNMENT CHECK AND

ADJUSTMENT
1. Measure the wheel alignment with the
vehicle parked on a level surface.
2. The front suspension, steering system, and
wheels should be serviced to normal condi-
tion prior to measurement of wheel align-
ment
TOE-IN
Standard value :
Toe-in -0.05° ± 0.05°
NOTE
(1) If the toe-in is not within the standard value,
adjust the toe-in by undoing the clips and
turning the left and right tie rod turn buckles
T
by the same amount (in opposite directions).
Symbol Description
AF
A Clip
B Tie rod turn buckle
(2) The toe will move out as the left turn buckles
is turned toward the front of the vehicle and
the right turnbuckle is turned toward the
DOIMC33AR08014
rear of the vehicle.
R
For each one turn of the left and right tie

rods, the toe-in will be adjusted by ap-
prox.1°05' (per wheel).
STEERING ANGLE
D
Standard value:
Inner 32.7° ± 1° + 0.5°

wheel : - 1.0°
Outer 38.9° ± 1° + 0.5°
wheel : - 1.0°
CAMBER AND CASTER

Standard value:
Camber - 0.4° ± 0.5°
(Allowed difference
between right and left
angle: 30')
Caster 3.0° ± 1.0°
(Allowed difference
between right and left
angle: 30')

NOTE
(1) Camber and caster are preset at the factory
and cannot be adjusted.
(2) If camber is not within the standard value,
check and replace bent or damaged parts.
CAUTION
(1) To prevent the wheel bearing damage, never
subject the wheel bearings to the vehicles
load when the drive shaft nuts are loosened
(2) Do not knock at stabilizer bracket and
bracket brake
T
AF
R
D

/6 STRUT ASSEMBLY
STRUT ASSEMBLY WCH33ASASSY12001
T
AF
R
DOIQC33AR12001
D
• Front wheel alignment adjustment (Refer to page 33A/4 )
Removal steps
1. ABS sensor front connection
2. Brake hose clamp
3. Stabilizer link connection
4. Strut and knuckle connection bolt
5. Nut
6. Strut assembly
T2 : 8.0~10.0 kgm (80~100 Nm, 57.86~72.33 ft.lbs)

STRUT ASSEMBLY /7
STABILIZER LINK DISCONNECTION

Use the ring spanner and Allen key to remove
stabilizer linknut.
Symbol Description
A Ring spanner
B Allen key
C Stabilizer link nut
DOIQC33AR12002
STRUT ASSEMBLY REMOVAL

1. Hang the knuckle assembly by wire as shown
T
AF
DOIQC33AR12003
2. Remove the strut upper nuts (3 pieces).
Symbol Description
R
A Strut upper nuts

D
DOIQC33AR12004
3. Remove the strut assembly from the strut

housing.
INSPECTION
• Check for oil leaks from the strut assembly.
• Check the strut assembly for damage, scratch
or deformation.
• Check the spring or damage and corrosion.
DOIQC33AR12005

/8 STRUT ASSEMBLY

STRUT ASSEMBLY INSTALLATION
strut assembly.
STABILIZER LINK CONNECTION

stabilizer link connection.
T
AF
R
D

STRUT ASSEMBLY /9
DISASSEMBLY AND REASSEMBLY WCH33ASASSY12002
T
AF
R
DOIQC33AR12006
D
Disassembly steps
1. Dust cover
2. Self locking nut
3. Strut mounting assy
4. Strut mounting bearing
5. Upper spring seat, front
6. Upper spring insulator, front
7. Spring, front
8. Bump stopper, front
9. Strut assy

/ 10 STRUT ASSEMBLY
DISASSEMBLY SERVICE POINT

WCH33ASPROC12003
SELF-LOCKING NUT REMOVAL

1. Before disassembling the strut, make sure
mark the strut mounting assy and lower
spring seat with white mark. This procedure
is to align strut mounting assy and lower
spring seat during installation.
Symbol Descriptions
A Marking
B Center line
C Strut mounting assy
D Lower spring seat
T
AF
DOINC33AR08003
2. By using the special tools MB991237 and

MB991238, compress the front spring.
R
CAUTION
(1) Install the special tools evenly so that
the maximum length will be attained
within the installation range.
D
(2) Do not use an impact wrench to tighten

the special tool bolt.
DOINC33AR09009
3. Holding the strut assy with the allen key,

then loosen the self locking nut.
Symbol Description
A Allen key
CAUTION
(1) Do not use impact wrench to loosen the
self-locking nut.
(2) Do not compress coil until coil to coil
contact.
DOINC33AR09010

STRUT ASSEMBLY / 11
INSPECTION
• Check the strut mounting bearing for wear
or rust.
• Check the strut mounting assy for wear or
rust.
• Check the rubber parts for damage or deteri-
oration.
• Check the spring for deformation deteriora-
tion or damage.
• Check the shock absorber for deformation.
DOINC33AR09011
STRUT CHECK FOR GAS LEAK AND JERKING

1. To check on gas leak, compress the rod to
the minimum length and release it.
2. If the rod does not rebound back to the
maximum length, the strut is defective.
NOTE :
T • Since tester may feel loss of compression

and rebound at initial period due to in-
ternal air pocket caused by prolong
AF
storage, test the upward position.
3. To check jerking, press and pull rod a few
DOINC33AR08005 times (at least 5 times).
4. If jerking exist, the phenomena of sudden
lost of compression, and rebound will appear
means that strut is defective.
R
D

/ 12 STRUT ASSEMBLY
REASSEMBLY SERVICE POINT

SELF-LOCKING NUT INSTALLATION
1. Install the bump stopper, spring , upper
spring insulator, upper spring seat, strut
mounting bearing and strut mounting assy.
A Bump stopper
B Front spring
C Front upper spring insulator
D Front upper spring seat
E Strut mounting bearing
F Strut mounting assy
G Self-locking nut
2. With the front spring held compressed by
the special tools MB991237 and MB991238,
provisionally tighten the self-locking nut 2
T or 3 times.
CAUTION
Do not use impact wrench to tighten the
AF
special tool bolt.
DOINC33AR08004
3. Align the white marking of the strut

mounting assy with the marking of the strut
lower spring seat.
R
Symbol Descriptions
A Marking
D
B Center line
C Strut mounting assy
D Lower spring seat
4. Correctly align both ends of the front spring
with the grooves in the upper spring seat
and lower spring seat.
DOINC33AR08003

STRUT ASSEMBLY / 13
5. Hold the strut assy with allen key and then

tighten the self-locking nut.
Symbol Description
A Allen key
DOINC33AR09010
6. By using the special tool and torque wrench,

tighten the self-locking nut.
Specfied torque:
5.5 kgm (55 Nm, 39.78 ft.lbs) ± 0.5 kgm (5
Nm, 3.62 ft.lbs)
CAUTION
T Do not use impact wrench to tighten the

self-locking nut.
AF
DOINC33AR09012
R
D

/ 14 LOWER ARM
LOWER ARM WCH33ASASSY12003
T
AF
R
DOIQC33AR12007
D
• Front wheel alignment adjustment (Refer to page 33A/4 )
Removal steps
1. Lower arm ball joint connection bolt
2. Lower arm front bushing connection bolt
3. Lower arm rear bushing connection bolt
4. Lower arm assembly
5. Ball joint
T1: 8.0~10.0 kgm (80~100 Nm, 57.86~72.33 ft.lbs)

LOWER ARM / 15
LOWER ARM BALL JOINT CONNECTION

BOLT REMOVAL
1. Remove the lower arm ball joint connection
bolt and nut.
DOIQC33AR12008
2. Pull down the lower arm assembly as shown

T
AF
DOIQC33AR12009
LOWER ARM ASSEMBLY REMOVAL

1. Remove the lower arm rear bushing connec-
R
tion bolt.
D
DOIQC33AR12010
2. Remove the lower arm front bushing connec-

tion bolt.
3. Remove the lower arm assembly.
DOIQC33AR12011

/ 16 LOWER ARM
BALL JOINT REMOVAL

1. Remove the ball joint bolt (3 pieces) and nut
(3 pieces) from the lower arm.
DOIQC33AR12012
2. By using screw driver, pry out the ball joint.

NOTE:
Do not reused the bolt and nut.
T
AF
DOIQC33AR12013
INSPECTION
BALL JOINT CHECK
R
Check the ball joint angle. If the measured angles

are over standard value, replace the ball joint.
Standard value:
22° minimum (All around).
D
LOWER ARM ASSEMBLY CHECK

• Check the bushing for wear and deteriora-
tion.
• Check the lower arm for bend or breakage.
DOIQC33AR12014
• Check the ball joint dust cover for cracks.
• Check all bolts for condition and straightness.
LOWER ARM BALL JOINT CONNECTION
BOLT INSTALLATION
Reverse order procedure removal to install lower
arm ball joint connection bolt.
LOWER ARM ASSEMBLY INSTALLATION

Reverse order procedure removal to install lower
arm.

LOWER ARM / 17
BALL JOINT INSTALLATION

Reverse order procedure removal to install ball
joint.
T
AF
R
D

/ 18 STABILIZER BAR
STABILIZER BAR WCH33ASASSY12004
T
AF
R
DOIQC33AR12015
D

• Front sub frame removal and installation, refer to GROUP 032 – Front sub frame.
Removal steps
1. Stabilizer link
2. Stabilizer clamp
3. Bush
4. Stabilizer bar

STABILIZER BAR / 19

WCH33ASPROC12005
STABILIZER BUSH AND CLAMP

INSTALLATION
1. Fit the bush to the stabilizer bar.
2. Install the clamp as shown in the illustration.
3. Tighten the bolt to the specified torque.
Specified torque: 4.5 kgm (45 Nm, 32.55
ft.lbs) ± 0.5 kgm (5 Nm, 3.62 ft.lbs)
1 Bush
2 Stabilizer bar
3 Clamp
4 Bolt
5 Sub-frame
6 Stabilizer bar restrictor
T
AF
DOIQC33AR12016
INSPECTION
STABILIZER LINK BALL JOINT CONTINUOUS
R
ROTATING TORQUE INSPECTION

1. Shake the stabilizer link ball joint stud several
times before installing the nut to the stud.
D
Then use the special tool to measure the

continuous rotating torque of the stabilizer
link ball joint.
Continuous rotating torque:
0.06~0.13 kgm (0.6~1.3 Nm, 0.43~0.94 ft.lbs)
DOIMC33AR08012 2. If the turning torque exceeds the standard

value, replace the stabilizer link.
3. If the turning torque is lower than the
standard value, check that the ball joint for
loosenes if there is no loosen, it possible to
use the stabilizer link.

/ 20 STABILIZER BAR
STABILIZER LINK BALL JOINT CHECK

Check the stabilizer link ball joint angle. If the
measured angles are over then standard value,
replace the stabilizer link.
Standard value:
28° Minimum (All around)
DOIQC33AR12018
T
AF
R
D

REAR SUSPENSION 34
Content /1
34 REAR SUSPENSION
SPECIFICATIONS ....................................................................... 34/2
SERVICE SPECIFICATIONS ......................................................... 34/2
SPECIAL TOOLS ........................................................................ 34/2

TOOLS ................................................................................. 34/2

SYMPTOM ............................................................................ 34/3

REAR WHEEL ALIGNMENT CHECK AND ADJUSTMENT ..................... 34/3
CAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34/3
TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34/5
CONTROL LINK, UPPER LINK AND LOWER ARM ................................ 34/6

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34/8
TRAILING ARM .........................................................................

T 34/9
34/9
AF
INSPECTION .......................................................................... 34/10
STRUT ASSEMBLY ..................................................................... 34/11

INSPECTION ......................................................................... 34/12
R

DISASSEMBLY SERVICE POINTS ................................................... 34/14
D
REASSEMBLY SERVICE POINTS .................................................... 34/14

INSPECTION .......................................................................... 34/15
STABILIZER BAR ....................................................................... 34/17

INSPECTION .......................................................................... 34/18
STABILIZER LINK BALL JOINT CONTINUOUS ROTATING TORQUE INSPECTION . . . . . . . . . 34/18
STABILIZER LINK BALL JOINT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34/18
REAR CROSSMEMBER MODULE ................................................... 34/19


34 REAR SUSPENSION
/2 SPECIFICATIONS
Items Specification
Suspension system Trailing arm with multi-link type
Coil spring Wire dia x I.D. x free length 10.2 mm (0.4 in) x 75.8 mm (2.98 in) x 387
mm (15.24 in)
Identification colour Yellow
Load rate 19 ± 0.95 N/mm
Shock absorber Type Gas cylindrical double acting type
Stroke 155.21 mm (6.11 in)
Damping force [at 0.3 m/sec.]
Expansion 73 ± 12 kgf
Contraction 62 kgf ± 12 kgf
Items Value Allowance
Standard value
Toe in
Camber (The difference
0.1 mm (0.004 in)
T ± 0.1 mm (0.004 in)

+ 0.5°
AF
between the left and
right wheels should be - 1.5°
- 0.1°
(1)
30 m/sec. or less.)
Stabilizer link ball stud
for continuous rotating 7~20 kgf.cm
torque
R
NOTE:
(1) Specified values are applicable in the condition of :- Vehicle weight — Kerb weight
SPECIAL TOOLS
D
WCH034STOOL12001
TOOLS
A: Spring compressor
A: MB991237 Compression of the rear coil
body
B: MB991239 spring
B: Arm set
DOIIC33AR9003

REAR SUSPENSION 34
TROUBLESHOOTING /3
MB990326 Preload socket
Checking of the stabilizer

DOIIC034R9003
link ball joint continuous ro-
tating torque
MB990685 Torque wrench
DOIIC034R9004
SYMPTOM
Symptom
T
Probable cause
Broken or deteriorated coil spring Replace
Remedy
AF
Shock absorber malfunction
Poor riding Over inflation pressure of tyre Refer to MODULE 1.8,
GROUP 031 – Wheel &
tyre.
Body tilting Broken or deteriorated coil spring Replace
Lack of lubrication Lubricate
R
Looseness and wear Retighten or replace

Noise
Broken or deteriorated coil spring Replace
Shock absorber malfunction
D
REAR WHEEL ALIGNMENT CHECK AND

ADJUSTMENT
Measure the wheel alignment with the vehicle
parked on level ground.
The rear suspension and wheels should be ser-
viced to the normal condition prior to measure-
ment of wheel alignment.
CAMBER
Standard value:
Allowance + 0.5°
-1.5°
Allowance - 0.1°
Camber The difference between the left
and right wheels should be 30’
or less.

34 REAR SUSPENSION
/4 TROUBLESHOOTING
If the camber is not within the standard value,

adjust by the following procedure.
1. Remove the connection between the control
link and the trailing arm.
DOIQC034R12012
2. Adjust the camber by turning the camber

adjusting bolt [The mounting bolt on the
inside of the lower arm].
T
AF
DOIQC034R12010
3. Tighten the adjusting bolt nut to the spe-

R
cified torque.
Specified torque:
8.0~10.0 kgm (80~100 Nm, 57.86~72.33 ft.lbs)
D
DOIQC034R12011

REAR SUSPENSION 34
TROUBLESHOOTING /5
4. Tighten the control link to body connection

Specified torque:
2.0~3.0 kgm (20~30 Nm, 14.47~21.7 ft.lbs)
5. After adjusting the camber, be sure to adjust

the toe-in.
DOIQC034R12013
TOE-IN
Standard value:
Value Allowance
0.1 mm (0.004 in) 0.1 mm (0.004 in)
T
If the toe-in is not within the standard value,
adjust by the following procedure.
1. Be sure to adjust the camber before adjusting
the toe-in.
AF
2. Adjust by turning the toe adjusting bolt
[mounting bolt on the inside of the control
DOIQC034R12014
link].
3. Tighten the adjusting bolt nut to the spe-
cified torque.
Specified torque:
R
8.0~10.0 kgm (80~100 Nm, 57.86~72.33 ft.lbs)

D
DOIQC034R12015

34 REAR SUSPENSION
/6 CONTROL LINK, UPPER LINK AND LOWER ARM
CONTROL LINK, UPPER LINK AND LOWER ARM WCH034SASSY12001
T
AF
R
DOIQC034R12001
D
• Wheel alignment check and adjustment (Refer to page 34/3 ).
Control link removal steps
1. Control link and rear crossmember connection bolt
2. Control link and trailing arm connection bolt
3. Control link
Upper link removal steps
4. Upper link and rear knuckle connection bolt
5. Upper link
Lower arm removal steps
6. Stabilizer link and lower arm connection
7. Lower arm and rear crossmember connection bolt
8. Shock absorber assembly and lower arm connection bolt
9. Lower arm and rear knuckle connection bolt
10. Lower arm.
CAUTION
* Indicates part which should be temporarily tightened, and then fully tightened with the
vehicle on the ground in unladen condition.

REAR SUSPENSION 34
CONTROL LINK, UPPER LINK AND LOWER ARM /7
T1: 2.0~3.0 kgm (20~30 Nm, 14.47~21.7 ft.lbs)

T2*: 8.0~10.0 kgm (80~100 Nm, 57.86~72.33 ft.lbs)
T3: 3.5~4.5 kgm (35~45 Nm, 25.32~32.55 ft.lbs)
T
AF
R
D

34 REAR SUSPENSION
/8 CONTROL LINK, UPPER LINK AND LOWER ARM
CONTROL LINK/LOWER ARM REMOVAL

After marking mating mark on the toe-in or
camber adjusting bolt, remove the control link
and lower arm.
Symbol Description
A Alignment mark on rear
cross-member
B Alignment mark on toe-in or
DOIQC034R12016
camber adjusting bolt
C Toe-in or camber adjusting
bolt
INSPECTION
tion.
• Check the control link and lower arm for
T
bends or breakage.
• Check all bolts for condition and straightness.
AF
R
D

REAR SUSPENSION 34
TRAILING ARM /9
TRAILING ARM WCH034SASSY12002
T
AF
R
DOIQC034R12002
D

• Wheel alignment and adjustment (Refer to page 34/3 .)
1. Brake tube
2. Clip hose
3. Brake hose
4. Parking brake cable
5. Control link and trailing arm connection bolt
6. Trailing arm and knuckle connection bolt
7. Trailing arm and body connection bolt
8. Trailing arm
CAUTION
* Indicates parts which should be temporarily tightened, and then fully tightened with the
vehicles on the ground in the unladen condition.
T1: 2.0~3.0 kgm (20~30 Nm, 14.47~21.7 ft.lbs)
T2: 9.5~11.0 kgm (95~110 Nm, 68.71~79.56 ft.lbs)
T3*: 11.0~13.0 kgm (110~130 Nm, 79.56~94.03 ft.lbs)

34 REAR SUSPENSION
/ 10 TRAILING ARM
LIFTING POINT
1. When removing the trailing arm, move the
lifting arm slightly towards the front of the
vehicles so that it will not be in the way.
INSPECTION
• Check the trailing arm for bending or dam-
age.
DOIQC034R12003
tion.
T
AF
R
D

REAR SUSPENSION 34
STRUT ASSEMBLY / 11
STRUT ASSEMBLY WCH034SASSY12003
T
AF
R
DOIQC034R12004
D
• Removal and Installation of Trim rear end, Trim quarter front and Trim quarter rear (Refer to
MODULE 1.10, GROUP 52A-Trunk room trim.
Disassembly steps
1. Self-locking flange nut
2. Shock absorber assembly and lower arm connection bolt
3. Strut assembly
* Indicates parts which should be temporarily tightened, and then fully tightened with the vehicles
on the ground in the unladen condition.
T1 : 4.0~5.0 kgm (40~50 Nm, 28.93~36.16 ft.lbs)
T2*: 8.0~10.0 kgm (80~100 Nm, 57.86~72.33 ft.lbs)

34 REAR SUSPENSION
/ 12 STRUT ASSEMBLY
STRUT ASSEMBLY REMOVAL

1. Remove the strut upper self locking nuts.
DOIQC034R12019
2. Remove the strut lower connecting bolt.
T
AF
DOIQC034R12018
3. Using the bar pull down the lower arm to

remove the strut assembly.
INSPECTION
R
• Check the rubber parts for cracks and wear.

• Check the shock absorber for malfunctions ,
oil leakage or abnormal noise.
D

STRUT ASSEMBLY INSTALLATION
Reverse order procedure removal to install the
DOIQC034R12005 strut assembly.

REAR SUSPENSION 34
STRUT ASSEMBLY / 13
T
AF
R
DOIQC034R12006
D
Disassembly steps
1. Self-locking nut
2. Washer
3. Upper bushing B
4. Rubber ring
5. Spring bracket
6. Spring pad
7. Upper bushing A
8. Collar
9. Cup
10. Dust cover
11. Bump rubber
12. Coil spring
13. Shock absorber

34 REAR SUSPENSION
/ 14 STRUT ASSEMBLY
DISASSEMBLY SERVICE POINTS

WCH034SPROC12005
SELF-LOCKING NUT REMOVAL

1. Use the special tools to compress the coil
spring.
CAUTION
(1) Install the special tools evenly so that
the maximum length will be attained
within the installation range.
(2) Do not use impact wrench to tighten the
DOIIC034R9030
special tool bolt.
2. Holding the piston rod, remove the self-

locking nut.
CAUTION
Do not use impact wrench to remove the
self-locking nut.
T
AF
DOIIC034R9031
SHOCK ABSORBER REMOVAL

R
To discard the low pressure gas-filled shock ab-

sorber, place the assembly horizontally with its
piston rod extended. Then drill a hole approx.
3 mm (0.12 in) in diameter at the location shown
D
to discharge the gas.

CAUTION
The gas itself is harmless, but it may issue out
of the hole together with chips generated by
the drill. Therefore, be sure to wear goggles.
DOIIC034R9032
REASSEMBLY SERVICE POINTS

COIL SPRING INSTALLATION
1. During install the coil spring, make sure the
marking mark facing upward (Example Batch
No: 7CE77/05–A).
DOIHC034R04009

REAR SUSPENSION 34
STRUT ASSEMBLY / 15
2. Use the special tools (MB9912337, MB991239)

to compress the coil spring, then install it to
the shock absorber.
CAUTION
Do not use an impact wrench to tighten the
bolt of the special tool.
3. Align the end of the coil spring with the
stepped section of the spring seat of the
shock absorber.
Symbol Description
Straight line going through the
A center of the spring bracket
mounting bolt
B Lower bushing inner pipe
C Self-locking nut
D Spring bracket
E Spring bracket mounting bolts
T
F Spring pad
G Dust cover
H Coil spring
AF
I Lower bushing
DOIGC034R03003 SPRING PAD INSTALLATION

Align the stepped section of the spring pad with
the end of the coil spring, then install the spring
pad.
R
SPRING BRACKET INSTALLATION

Install the bracket with line aligned with the
D
center axis of the lower bushing inner pipe.
SELF-LOCKING NUT INSTALLATION

1. Provisionally tighten the self-locking nut.
2. Remove the special tools (MB991237,
MB991239), tighten the self-locking nut to
Specified torque:
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.5 kgm (5
Nm, 3.62 ft.lbs)
CAUTION
Do not use an impact wrench to either
tighten the self-locking nut or to remove the
special tool.
INSPECTION
• Check the rubber parts for damage.

34 REAR SUSPENSION
/ 16 STRUT ASSEMBLY
• Check the coil spring for crack, damage or

deterioration.
• Check the oil leaks from the strut assembly.
T
AF
R
D

REAR SUSPENSION 34
STABILIZER BAR / 17
STABILIZER BAR WCH034SASSY12005
T
AF
R
DOIQC034R12007
D
• Wheel alignment check (Refer to page 34/3 ).
Removal steps
1. Self-locking nut
2. Joint cup
3. Stabilizer rubber
4. Stabilizer link
5. Fixture
6. Bushing
7. Stabilizer bar
T1: 1.7~2.6 kgm (17~26 Nm, 12.3~18.81 ft.lbs)
T2: 3.5~4.5 kgm (35~45 Nm, 25.32~32.55 ft.lbs)

34 REAR SUSPENSION
/ 18 STABILIZER BAR
STABILIZER LINK BALL JOINT CONTINUOUS

ROTATING TORQUE INSPECTION
1. Shake the stabilizer link ball joint stud several
times before installing the nut to the stud.
Then use the special tool to measure the
continuous rotating torque of the stabilizer
link ball joint.
Continuous rotating torque:
7 ~ 20 kgf.cm
DOIQC034R12008 2. If the turning torque exceeds the standard

value, replace the stabilizer link.
3. If the turning torque is lower than the
standard value, check that the ball joint for
looseness if there is no loosen, it is possible
to use the stabilizer link.
STABILIZER LINK BALL JOINT CHECK
Check the stabilizer link ball joint angle if the
T measured angle are upper than standard angle,

replace the stabilizer link.
Standard angle:
AF
± 28° Min (All around)
R
DOIQC034R12009
D

REAR SUSPENSION 34
REAR CROSSMEMBER MODULE / 19
REAR CROSSMEMBER MODULE WCH034SASSY12006
T
AF
R
DOIQC034R12017
D
CAUTION:
(1) * Indicates parts which should be temporarily tightened, and then fully tightened with the
vehicles on the ground in the unladen condition.
(2) The part indicated by ** is the bolt with friction coefficient stabilizer. In removal, ensure there
is no damage, clean dust and soiling from the bearing and thread surfaces, and tighten them

34 REAR SUSPENSION
/ 20 REAR CROSSMEMBER MODULE
• Front exhaust pipe removal (Refer to GROUP 15 - Exhaust Pipe and Main muffler 15/50 ).
• Rear stabilizer link removal (Refer to 34/17 ).
• Shock absorber assembly and lower arm connecting bolt removal (Refer to 34/11 ).
• Control link removal (Refer to34/6 ).
• Upper link removal (Refer to 34/6 ).
• Lower arm removal (Refer to 34/6 ).
• Lower arm installation (Refer to34/6 ).
• Upper link installation (Refer to 34/6 ).
• Control link installation (Refer to 34/6 ).
• Shock absorber assembly and lower arm connecting bolt installation (Refer to 34/11 ).
• Rear stabilizer link installation (Refer to 34/17 ).
• Front exhaust pipe installation (Refer to GROUP 15 - Exhaust Pipe and Main muffler 15/50 ).
• Rear wheel alignment check and adjustment (Refer to 34/3 ).
• Bleeding brake line procedure (Refer to 35A/16 ).
Removal steps
1. Brake tube
2. Clip hose
3. Brake hose
4. Speed sensor connector
5. Parking brake cable connection
6. Rear crossmember module
T
AF
T1*: 11.0~13.0 kgm (110~130 Nm, 79.56~94.03 ft.lbs)
T2**: 11.0~14.0 kgm (110~140 Nm, 79.56~101.26 ft.lbs)
R
D

REAR SUSPENSION 34
REAR CROSSMEMBER MODULE REMOVAL

1. Remove front exhaust pipe assembly.
DOIQC034R12020
2. Remove the stabilizer link connection nut RH

and LH side.
T
AF
DOIQC034R12021
3. Remove the strut lower connecting bolt RH

and LH side.
R
D
DOIQC034R12018
4. Support the transmission jack under the

crossmember.
DOIQC034R12022

34 REAR SUSPENSION
5. Remove the brake tube connection RH and

LH side .
DOIQC034R12023
6. Remove the clip hose RH and LH side.
T
AF
DOIQC034R12024
7. Disconnect the speed sensor connector RH

and LH side .
R
D
DOIQC034R12025
8. Release the brake cable connection RH and

LH side.
DOIQC034R12026

REAR SUSPENSION 34
9. Remove the brake cable bracket RH and LH

side .
DOIQC034R12027
10. Remove the trailing arm and body connec-

tion bolt RH and LH side.
T
AF
DOIQC034R12028
11. Remove the all crossmember bolts.

R
D
DOIQC034R12029
12. Remove the crossmember from the vehicle.
DOIQC034R12030

34 REAR SUSPENSION

REAR CROSSMEMBER MODULE
INSTALLATION
the crossmember module.
2. Detail procedure for bleeding brake line
(Refer to 35A/16 ).
3. Detail procedure for wheel alignment check
and adjustment (Refer to 34/3 ).
DOIQC034R12030
T
AF
R
D

BASIC BRAKE SYSTEM 35A
Content /1
35A BASIC BRAKE SYSTEM

MASTER CYLINDER ................................................................. 35A/4
BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/4
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/4
REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/4
WHEEL SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/4
CONSTRUCTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/5
SERVICE SPECIFICATIONS ............................................................ 35A/5
SPECIAL TOOLS ........................................................................ 35A/6

TOOLS ................................................................................. 35A/6
TROUBLESHOOTING ................................................................. 35A/8

BRAKE PEDAL CHECK AND ADJUSTMENT ..................................... 35A/9
STOP LAMP SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/10
BRAKE BOOSTER OPERATING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/10
BRAKE FLUID LEVEL SENSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/11
T
FRONT DISC BRAKE PAD CHECK AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE DISC THICKNESS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE DISC RUN-OUT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35A/11
35A/13
35A/13
35A/13
AF
FRONT BRAKE DISC RUN–OUT CORRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/14
REAR DISC BRAKE PAD CHECK AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/15
BLEEDING ............................................................................. 35A/16
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/16
BLEEDING OF MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/17
BRAKE PIPE LINE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/17
R
BRAKE PEDAL [ FOR MT ] ............................................................ 35A/19

DISASSEMBLY AND REASSEMBLY ................................................ 35A/20
D
BRAKE PEDAL [ FOR M/T ] .......................................................... 35A/22

STOP LAMP SWITCH CONTINUITY CHECK ..................................... 35A/22
BRAKE PEDAL [ FOR CVT] ........................................................... 35A/23

BRAKE PEDAL [ FOR A/T ] ........................................................... 35A/26

STOP LAMP SWITCH CONTINUITY CHECK ..................................... 35A/26
MASTER CYLINDER AND BRAKE BOOSTER ...................................... 35A/27

MASTER CYLINDER .................................................................. 35A/28

DISASSEMBLY AND REASSEMBLY OF MASTER CYLINDER .................. 35A/28
FRONT DISC BRAKE ................................................................... 35A/29


/2 Content
FRONT BRAKE CALIPER ASSEMBLY ................................................ 35A/31

LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/33
FRONT BRAKE ASSEMBLY ........................................................... 35A/35

FRONT DISC BRAKE PAD CHECK AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/35
REAR DISC BRAKE ..................................................................... 35A/37

REAR DISC BRAKES ................................................................... 35A/38

LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A/39
REAR DISC BRAKE ..................................................................... 35A/40

T
AF
R
D

Content /3
NOTE
T
AF
R
D

The ABS consist of components such as the wheel speed sensors, stop lamp switch, hydraulic unit as-
sembly (integrated with the ABS-ECU) and the ABS warning lamp. If a problem occurs in the system,
the manufacturing component can be identified and the trouble symptoms will be memorized by the
diagnosis codes , service data and actuator testing are possible by using the PADT-07.
MASTER CYLINDER
Type Tandem Center Valve
I.D. 23.8 mm (0.94 in)
BRAKE BOOSTER
Type Vacuum type, Single
Effective dia. of diaphragm 10 inches
Boosting ratio 8.0
FRONT DISC BRAKES
Items
Type
Disc effective dia. x thickness
T Specifications
Ventilated disc
281 mm (11.06 in) x 24 mm (0.94 in)
AF
Piston I.D 57 mm (2.24 in)
Pad thickness 10 mm (0.39 in)
Min Disc thickness 22.4 mm (0.88 in)
Limit 1.6 mm (0.063 in)
Clearance Adjustment Automatic
R
REAR DRUM BRAKE

D
Type Leading trailing

Drum I.D 230 mm (9.06 in)
Wheel cylinder I.D 22.2 mm (0.87 in)
Lining thickness 4.5 mm (0.18 in)
Clearance Adjustment Automatic
WHEEL SPEED SENSOR
Type Pasline
Rotor teeth front and rear 46

SERVICE SPECIFICATIONS /5
T
AF
R
DOINC35AR08001
Symbol Description
1 Hydraulic unit
D
2 Wheel speed sensor/ ABS rotor front

3 Duplex Module
4 Master cylinder
5 Wheel speed sensor/ ABS rotor rear
SERVICE SPECIFICATIONS WCH35ASPECS11001
SPECIFICATIONS
Items Standard value Limit
Brake pedal height MT 299 mm (11.77 in) ± 1 —
AT 299.7 mm (11.8 in) ± 1 —
Brake pedal free play 3 - 8 mm (0.12 - 0.31 in) —
Brake pedal to floor board clearance 80 mm (3.15 in) —
Wheel speed sensor's internal resistance 1.28-1.92 kΩ —
Wheel speed sensor's insulation resistance 100 kΩ or more —

/6 SPECIAL TOOLS
LUBRICANT
Items Specified Lubricant
Brake Fluid DOT3 or DOT4
Brake piston free play
Guide pin boot inner surfaces
Lock pin boot inner surfaces
Piston boot mounting grooves Repair kit grease
Brake piston boot inner surfaces
Pad assembly and shim contact surfaces
Lock pin sleeve
SEALANT
Thread part fitting 3M ATD Part No.8661 or equivalent Semi-drying sealant
TOOLS
Tool Number
MD998916
T Name
Socket Wrench
Use
To press clip spring at rear
AF
drum
DOIJC35BR04041
R
MB990784 Ornament remover Removal of brake caliper

oil seal
D
DOIIC042R9001
MB990241 Axle shaft puller Removal of the drum

brake
DOIIC026R9004
Brake piston retraction

EZT 0010
tool
EZT 0010–1R Shaft RH & Slot RH To rotate brake piston into
EZT 0010–2L Shaft LH & Slot LH caliper assy.
EZT 0010–3 Plate
DOIHC35BR05012 EZT 0010– 4 Adaptor

SPECIAL TOOLS /7
interface (VCI)
DOIMC35BR11039

CD
DOIMC35BR11042
T
connector; 1 m) VCI
DOIMC35BR11041
AF
EZT0047 USB cable (1.8 m)
PC and VCI
R
DOIMC35BR11046
D

DOIMC35BR11045

Ethernet cable
ing to VCI
DOIMC35BR11040

Cable keeper
cable messy
DOIMC35BR11043

/8 TROUBLESHOOTING

DOIMC35BR11044
DOIMC35BR11047
Symptom Probable Causes Remedy

Calliper improperly mounted
T
Loosen calliper mounting bolts
Unevenly worn or checked brake disc
Correct
Retighten
Replace
AF
Seized lining contact surface Replace
Noise and shock when brakes
Excessive calliper to pad assembly clearance Correct
applied
Uneven lining contact Correct
Broken shoe hold-down pin Replace
Lack of grease in sliding parts Lubricate
R
Loose suspension parts Retighten

Difference in left and right tire inflation pressure Adjust
Vehicle pulls one side when Inadequate contact of lining Correct
D
brakes applied Grease or fluid on lining surface Replace

Poor auto adjuster mechanism operation Correct
Insufficient or deteriorated brake fluid Replenish or change
Air in brake system Bleed the system
Poor brake booster operation Correct
Inadequate contact of lining Correct
Insufficient braking force Grease or fluid on lining surface Replace
Poor auto adjuster mechanism operation Correct
Vapor lock, mainly due to dragging of pad Correct
Clogged brake line Correct
Poor proportioning valve operation Replace
Air in brake system Bleed the system
Increased pedal stroke (Re- Brake fluid leaks from brake system Correct
duced pedal-to floor panel
clearance) Poor auto adjuster mechanism operation Correct
Excessive push rod-to piston clearance Adjust

Incomplete release of parking brake Correct

Incorrect parking brake adjustment Adjust
Deteriorated brake pedal return spring Replace
Clogged master cylinder return port Correct
Brake drag
Lack of grease in sliding parts Lubricate
Malfunctions of master cylinder check valve or
Replace
piston return spring.
Insufficient push rod to piston clearance Adjust
Early locking of rear brakes Malfunctions of proportioning valve Replace
BRAKE PEDAL CHECK AND ADJUSTMENT

1. Measure the brake pedal height as illus-
trated. If the brake pedal height is not within
the standard value, adjust or replace.
Symbol Description
T A
B
C
Operating rod
Operating rod lock nut
Stop lamp switch
AF
DOIQC35AR11011 D Brake pedal stroke
Standard value (D):
CVT 135 mm (5.31 in) ± 3 mm (0.12 in)
MT= (133.3 ± 1) mm.
1.1 Disconnect the stop lamp switch con-

R
nector.
1.2 Adjust the brake pedal height by turn-
ing the operating rod with pliers (with
D
the operating rod lock nut loosened),

until the correct brake pedal height is
obtained.
Symbol Description
A Pedal down
B Pedal up
C Lock nut
DOIIC35AR9006
1.3 Secure by tightening the lock nut of the
operating rod.
1.4 Push the stop lamp switch in the direc-
tion of the pedal stroke until it stops. (
The switch will slide if it is pushed
firmly.)
1.5 Connect the connector of the stop lamp
switch.
1.6 Check that the connector of the stop
lamp switch is not illuminated with the
brake pedal unpressed.

2. Start the engine and depress the brake pedal

with the approximately 49.0 kg (490 N,
108.04 lbs) of force, and measure the clear-
ance (A) between the brake pedal and the
floor board.
Standard :
If the clearance is outside the standard value,

check for air trapped in the brake line,
clearance between the lining and the drum
and dragging in the parking brake . Adjust
DOINC35AR08036 and replace defective parts as required.
Connect a circuit tester to the stop lamp switch,
and check whether or not there is continuity
when the plunger of the stop lamp switch is
pushed in and when it is released. The stop lamp
switch is in good condition if there is no continu-
T
ity when the plunger is pushed in to a depth of
within 4 mm (0.16 in) from the outer case edge
surface, and if there is continuity when it is re-
AF
leased
Symbol Description
DOINC35AR08017
A 4 mm (0.16 in)
B No continuity
C Continuity
R
BRAKE BOOSTER OPERATING TEST

For simple checking of the brake booster opera-
tion, carry out the following tests:
D
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
B No good

2. Stop the engine and 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 good, the booster per-
formance can be determined as good. If one
of the above three test is not good, check
T the valve vacuum hose or booster.
BRAKE FLUID LEVEL SENSOR CHECK

AF
Symbol Description
A Brake fluid level “MIN”
No continuity When brake fluid surface is
above “MIN”
Has continu- When brake fluid surface is be-
R
ity low “MIN”

D
DOINC35AR08018
FRONT DISC BRAKE PAD CHECK AND

REPLACEMENT
NOTE
The brake pads have wear indicators that contact
the brake disc when the brake pad thickness
becomes 2 mm (0.079 in) and emit a squealing
sound to warn the driver.
Symbol Description
A Pad
B Wear indicator
DOIIC35AR9019
C Brake disc
D New brake pad
E Worn brake pad

1. Check brake pad thickness through caliper

body check port.
Standard Value:
10 mm (0.39 in)
Limit :2.0 mm (0.079 in)
CAUTION
• When the limit is exceeded, replace the
pads at both sides, and also the brake pads
for the wheels on the opposite sides at the
same time.
• If there is a significant difference in the
DOINC35AR08021 thicknesses of the pads on the left and right
sides , check the sliding condition of the
piston and guide pin.
2. Remove lower guide pin screw and lift caliper
assembly brake pad.
CAUTION
Do not wipe off the special grease that is on
T
the lock pin or allow it to contaminate the
lock pin.
3. Remove the outer pad and Inner pad with
AF
indicator from caliper carrier.
4. In order to measure the brake drag torque
after pad installation, measure the rotary
—sliding resistance of the hub with the pads
DOINC35AR08019
removed. (Refer to 35B — Front disc brake
installation service point.)
5. Install the pads and the caliper assembly, and
R
then check the brake drag torque. (Refer to

35B — Front disc brake installation service
point.) — Front disc brake installation service
point.)
D
Symbol Description
A Brake pad
6. Measure thickness at the thinnest and worn
area of the pad. Replace pad asembly when
pad thinness is less than the limit value.
Limit : 2.0 mm (0.079 in)
DOINC35AR08020

INSPECTION
• Check cylinder for wear, damage or rust.
• Check piston surface for wear, damage or
rust.
• Check caliper body or sleeve for wear.
• Check pad for damage or adhesion of grease,
checkbacking metal for damage.
DOIMC35BR07015
BRAKE DISC THICKNESS CHECK

1. Using a micrometer, measure disc thickness
at eight positions, approximately 45° apart
and 10 mm (0.39 in) in from the outer edge
of the disc.
Brake disc thickness:
T Items
Front disc
Standard value Minimum
24.0 mm (0.94
in)
22.4 mm
(0.88 in)
AF
Thickness variation (at least 8 positions)
DOIIC35AR9023 The different between any thickness measure-
ments should not be more than 0.01 mm (0 in)
2. If the disc is beyond the limits for thickness,
remove it and install a new one. If thickness
variation exceeds the specification, replace
R
the brake disc or turn rotor with on the car

type brake lathe (“MAD,DL-8700PF” or
equivalent).
D
FRONT BRAKE DISC RUN-OUT CHECK

1. Remove the caliper support and then move
the caliper assembly upward and secure by
using wire.
2. Inspect the disc surface for grooves, cracks
and rust. Clean the disc thoroughly and re-
move all rusts.
NOTE :
Replace with new guide pin bolt after every
guide pin removal.
DOINC35AR08019

3. Place a dial gauge approximately 5.0 mm (0.2

in) from the outer circumference of the brake
disc, and measure the run-out of the disc.
Limit :
0.04 mm (0.002 in) or less
NOTE
Tighten the nuts in order to secure the disc
to the hub.
FRONT BRAKE DISC RUN–OUT CORRECTION
1. If the run-out of the brake disc is equivalent
DOINC35AR08040 to or exceeds the limit specification, change
the phase of the disc and hub . Then measure
the run-out again.
• Before removing the brake disc, chalk both
sides of the wheel stud on the side at which
run-out is greatest.
Symbol Description
T A Chalk mark
AF
DOINC35AR08041
• Remove the brake disc and then place a

R
dial gauge as shown in the illustration, then

move the hub in the axial direction and
measure the play.Limit : 0.01 mm (0 in)
If the play equivalent to or exceeds the limit
D
disassembly the hub knuckle and check each

part
• If the play does not exceed the limit specific-
ation install the brake disc at a position 180°
away from the chalk mark, and then check
run-out of the brake disc once again.
DOINC35AR08042

2. If the run-out cannot be corrected by chan-

ging the phase of the brake disc, replace the
disc or turn rotor with on the car type brake
lathe (“MAD,DL-8700PF or equivalent).
DOINC35AR08043
REAR DISC BRAKE PAD CHECK AND

REPLACEMENT
T
AF
DOIHC35BR05010
NOTE
The brake pads have wear indicators that contact
the brake disc when the brake pad thickness
R
becomes 2 mm (0.079 in) and emit a squealing

sound to worn the driver.
Symbol Description
D
1 Pad
2 Wear indicator
3 Brake disc
A When new
DOIIC35AR9019 B When Worn
1. Check brake pad thickness through caliper
body check port
CAUTION
(1) Unscrew and remove the housing fixing
screw from the lower guide bolt (where
necessary prevent the guide pins from
rotating with inappropriate spanner). Be
careful not to damage the dust cover.
(2) When the limit is exceeded, replace the
pads at both sides, and also the brake
pads for the wheels on the opposite
sides at the same time.
DOIHC35BR05016

(3) If there is a significant difference in the

thicknesses of the pads on the left and
right sides, check the sliding condition
of the piston and guide pin.
Standard Value:
10.1 mm (0.4 in)
Limit:
2.0 mm (0.079 in)
2. Remove lock pin, swivel the housing upward.

It may be necessary to disconnect the hand-
brake cable. Hang the housing with a wire
hook on the wheel arch or suspension strut.
CAUTION
Do not wipe off the special grease that is on
the lock pin or allow it to contaminate the
lock pin.
DOIKC35BR03005
T 3. Remove the following parts from caliper

AF
support:
1. Pad & wear indicator assembly
2. Pad assembly
4. In order to measure that brake drag torque
after pad installation, measure the rotary —
sliding resistance of the hub with the pads
R
removed. (Refer toWCH35BSASSY306 ”Install-

ation Service Point” on ).
5. Install the pads and the caliper assembly, and
then check the brake drag torque. (Refer to
D
WCH35BSASSY306”Installation Service Point”

DOIHC35BR05013 .
BLEEDING WCH35ASPROC11003
BRAKE FLUID
1. Before bleeding need to remove brake fluid
first as per shown in the illustration.
• Engine running.
• Brake fluid should always be at maximum
level in the reservoir tank.
• Ensure that there is no leakage around
the fluid brake distribution.
• Install a filter to the reservoir tank when
supplying brake fluid.
DOINC35AR08013 • Use the specified brake fluid , avoid using
a mixture of the specified brake fluid
with other fluid.

CAUTION
mixture of the specified brake fluid with other
fluid.
Specified brake fluid : DOT 3 or DOT 4
Symbol Description
A Bottle
B Reservoir tank
BLEEDING OF MASTER CYLINDER
The master cylinder used has no check valve , so
if bleeding is carried out by the following proced-
ure, bleeding of air from the brake pipeline will
become easier. (When brake fluid is not con-
tained in the master cylinder.)
1. Fill the reserve tank with brake fluid.
2. Keep the brake pedal depressed.
3. Have another person cover the master cylin-
der outlet with a finger.
T
4. With the outlet still closed, release the brake
pedal.
DOINC35AR08016
5. Repeat steps (2)–(4) three or four times to
AF
fill the inside of the master cylinder with
brake fluid.
BRAKE PIPE LINE BLEEDING
1. Open the cap (B) of the bleeding nipple(A)
Symbol Description
R
A Bleeding nipple
B Cap
D
DOINC35AR08014

2. Install hose (C) to the bleeding nipple as

Symbol Description
C Hose
T
AF
DOINC35AR08015
3. Brake system bleeding process require

manual bleeding process.
R
Symbol Description
1 Rear (LH)
2 Front (RH)
D
3 Front (LH)
4 Rear (RH)
DOINC35AR08037

BRAKE PEDAL [ FOR MT ] / 19
BRAKE PEDAL [ FOR MT ] WCH35ASASSY11003
T
AF
R
DOIQC35AR11002
D
• Instrument Under Cover Removal (Refer to GROUP 52A – Interior)
• Instrument Under Cover Installation (Refer to GROUP 52A – Interior)
Removal Steps
1. Member assy bracket support
2. Stop lamp switch
3. Brake pedal assy
T1 : 0.9 - 1.4 kgm (9 - 14 Nm, 6.51 - 10.13 ft.lbs)
T2 : 2.5 - 3.0 kgm (25 - 30 Nm, 18.08 - 21.7 ft.lbs)

/ 20 BRAKE PEDAL [ FOR MT ]
T
AF
R
D
DOIQC35AR11003

BRAKE PEDAL [ FOR MT ] / 21
—Grease: repair kit grease

—Non-reusable parts
Disassembly steps
1. Pin snap
2. Pin assy
3. Brake pedal shaft bolt
4. Return spring
5. Brake pedal assy
6. Pad bracket
T1 : 2.5 - 3.0 kgm (25 - 30 Nm, 18.08 - 21.7 ft.lbs)
T
AF
R
D

/ 22 BRAKE PEDAL [ FOR M/T ]
BRAKE PEDAL [ FOR M/T ]

WCH35ASPROC11004

STOP LAMP SWITCH REMOVAL
1. Disconnect stop lamp switch and remove the
stop lamp switch from the bracket member
Symbol Description
A Stop lamp switch
DOINC35BR09003 B Bracket assy member
STOP LAMP SWITCH CONTINUITY CHECK

1. Remove the stop lamp switch
Symbol Description
A Stop lamp switch
B Stop lamp switch harness
T connector (C-22)
AF
DOIQC35AR11004
2. Check continuity between the stop lamp

switch terminals 1 and 6.
R
Check Items Terminal No.

Continuity Terminal 1 → Terminal 6
A 4 mm (0.16 in)
D
B No continuity
C Continuity
OK: Continuity
switch terminal 3 and 4.
DOIQC35AR11005
Stop lamp
Terminal No.
switch button
Stop lamp
•Terminal 3 → terminal 4
switch button
no continuity
normal
Stop lamp
switch button
continuity
push
4. If the result deviates from the table above,
then the switch is malfunction.
Replace the switch.

BRAKE PEDAL [ FOR CVT] / 23
BRAKE PEDAL [ FOR CVT] WCH35ASASSY11005
T
AF
R
DOIQC35AR11006
D
• Instrument Under Cover Removal (Refer to GROUP 52A - Instrument Panel.)
Post-Installation Operation
• Instrument Under Cover Installation (Refer to GROUP 52A – Instrument Panel)
Removal steps
1. Member assy bracket support
2. Stop lamp switch
3. Brake pedal assy
T1 : 0.9 - 1.4 kgm (9 - 14 Nm, 6.51 - 10.13 ft.lbs)
T2 : 2.5 - 3.5 kgm (25 - 35 Nm, 18.08 - 25.32 ft.lbs)

/ 24 BRAKE PEDAL [ FOR CVT]
T
AF
R
D
DOIQC35AR11007

BRAKE PEDAL [ FOR CVT] / 25
—Grease: repair kit grease

—Non-reusable parts
Disassembly steps
1. Pin snap
2. Pin assy
3. Brake pedal shaft bolt
4. Return spring
5. Brake pedal assy
6. Pad bracket
T1 : 2.5 - 3.0 kgm (25 - 30 Nm, 18.08 - 21.7 ft.lbs)
T
AF
R
D

/ 26 BRAKE PEDAL [ FOR A/T ]
BRAKE PEDAL [ FOR A/T ]

WCH35ASPROC11005

STOP LAMP SWITCH REMOVAL
1. Disconnect stop lamp switch and remove the
stop lamp switch from bracket member as
Symbol Description
A Stop lamp switch
DOINC35BR09003 B Bracket assy member
STOP LAMP SWITCH CONTINUITY CHECK

1. Remove the stop lamp switch
Symbol Description
A Stop lamp switch
B Stop lamp switch harness
T connector (C-22)
AF
DOIQC35AR11004

switch terminals 1 and 6.
R
Check Items Terminal No.

Continuity Terminal 1 → Terminal 6
A 4 mm (0.16 in)
D
B No continuity
C Continuity
OK: Continuity
switch terminal 3 and 4.
DOIQC35AR11005
Stop lamp
Terminal No.
switch button
Stop lamp
switch button
no continuity
normal
Stop lamp
switch button
continuity
push
4. If the result deviates from the table above,
then the switch is malfunction.
Replace the switch.

MASTER CYLINDER AND BRAKE BOOSTER / 27
MASTER CYLINDER AND BRAKE BOOSTER WCH35ASASSY11007
T
AF
R
DOIQC35AR11008
D
— Non-reusable
Pre-Removal Operation
• Front Deck Garnish (Refer to Module 1.10 Group – 051)
• Windshield wiper (Refer to Module 1.10 Group 051)
• Front Washer (Refer to Module 1.10 Group 051)
• Brake fluid draining
• Brake line bleeding (Refer to Module 1.9 GROUP 35A).
• Brake Pedal Adjustment (Refer to Module 1.9 GROUP 35A).
Removal Steps
1. Hose reservoir (CVT) 7. Vacuum hose
2. Hose MT(Clutch) 8. Brake booster
3. Reservoir tank 9. Pin assy
4. Reservoir bracket assembly 10. Clevis pin
5. Tube assy 11. Gasket
6. Master cylinder assembly
T1 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T2 : 1.1 - 1.4 kgm (11 - 14 Nm, 7.96 - 10.13 ft.lbs)

/ 28 MASTER CYLINDER
MASTER CYLINDER WCH35ASASSY11008
DISASSEMBLY AND REASSEMBLY OF MASTER CYLINDER
T
AF
R
DOIQC35AR11009
D
Disassembly steps
1. Spring pin
2. Nipple assembly
3. Reservoir seal
4. Master cylinder body

FRONT DISC BRAKE / 29
FRONT DISC BRAKE WCH35ASASSY11009
T
AF
R
DOIQC35AR11010
D
• Draining of brake fluid
• Supplying brake fluid
• Bleeding brake lines
–Non-reusable parts
Removal steps
1. Connection for the brake hose
2. Gasket
3. Front disc brake
4. Front brake caliper assy
T1 : 9.5 - 11.0 kgm (95 - 110 Nm, 68.71 - 79.56 ft.lbs)
T2 : 2.7 - 3.1 kgm (27 - 31 Nm, 19.53 - 22.42 ft.lbs)

/ 30 FRONT DISC BRAKE

WCH35ASPROC11006
BRAKE DISC ASSEMBLY INSTALLATION

1. After installing the caliper support to the
knuckle , install the pad clips and the pads
to the caliper support.
CAUTION
• Do not let any oil, grease or other con-
tamination get onto the friction surfaces
of the pads and brake discs.
DOINC35AR08022
2. Clean piston and push back into the housing

cylinder with special tool.
3. Be careful that the dust cover does not be-
comes caught , when lowering the caliper
assembly, and tighten the slide pin to the
specified torque.
Tightening torque:
T 2.34 ~ 3.06 kgf.m
4. Check brake drag torque as follows.

AF
4.1 Start the engine and then depress the
brake pedal 2–3 times.
DOINC35AR09003 4.2 Stop engine.
4.3 Turn brake disc forward 10 times.
5. Use a spring balance to measure the rotation
sliding resistance of the hub in the forward
R
direction.
6. Calculate the drag force of the disc brake
[difference between of values measured in
item 6 and 1.].
D
Standard value :
30 kgf.cm
7. If the drag force of the disc brake exceeds

the standard value, disassemble piston and
clean piston. Check for corrosion or worn
DOINC35AR08022 piston seal, and check the sliding condition
of the slide pins.

FRONT BRAKE CALIPER ASSEMBLY / 31
FRONT BRAKE CALIPER ASSEMBLY WCH35ASASSY11010
T
AF
R
D
DOINC35AR08010

/ 32 FRONT BRAKE CALIPER ASSEMBLY
— Non reusable parts

• Post-installation Operation
• Brake fluid supplying
• Brake line bleeding
Removal Steps
1. Caliper body
2. Piston boot
3. Piston
4. Piston seal
5. Cap bleeder
6. Bleeder nipple
7. Pin / guide pin
8. Brake pad
9. Spring-pad
10. Caliper carrier
T
AF
R
D

FRONT BRAKE CALIPER ASSEMBLY / 33
LUBRICATION POINTS
T
AF
R
D
DOINC35AR08011

/ 34 FRONT BRAKE CALIPER ASSEMBLY
Symbol Description
Grease:Repair kit grease
Brake fluid:DOT3 or DOT4

A Repair kit grease
B Caution
The piston seal and boot kit are coated with special grease . Do
not wipe this grease off.
C Brake fluid:DOT3 or DOT4
T
AF
R
D

FRONT BRAKE ASSEMBLY / 35
FRONT BRAKE ASSEMBLY

WCH35ASPROC11007

FRONT DISC BRAKE PAD CHECK AND
REPLACEMENT
Detail procedures for removal front disc brake
pad and checking, refer to page WCH35AS-
PROC012
PISTON AND PISTON BOOT INSTALLATION
1. Install piston boot and piston to caliper body
Symbol Description
A Piston boot
B Piston
T
AF
R
D
DOINC35AR08033
2. Press the piston to the caliper body.

Caution
The piston and piston boot shall be properly
inserted in the caliper body.
DOINC35AR09016

/ 36 FRONT BRAKE ASSEMBLY
3. Push the piston using mallet and ensure the

piston is fully installed in the caliper body.
DOINC35AR09017
T
AF
R
D

REAR DISC BRAKE / 37
REAR DISC BRAKE WCH35ASASSY11011
T
AF
R
DOIQC35AR11012
D
Pre-removal steps
• Draining of brake fluid
• Supplying brake fluid
• Bleeding brake lines
Removal steps
1. Clip
2. Brake hose (brake pipe side ) connection
3. Brake hose
4. Rear brake caliper assembly
5. Rear brake disc
T1 : 9.5 - 11.0 kgm (95 - 110 Nm, 68.71 - 79.56 ft.lbs)
T2 : 2.7 - 3.1 kgm (27 - 31 Nm, 19.53 - 22.42 ft.lbs)

/ 38 REAR DISC BRAKES
REAR DISC BRAKES WCH35ASASSY11012
T
AF
R
DOINC35AR11004
D

• Post-installation Operation
• Brake fluid supplying
• Brake line bleeding
Removal Steps
1. Caliper body
2. Piston boot
3. Piston
4. Piston seal
5. Cap bleeder
6. Bleeder nipple
7. Pin / guide pin
8. Brake pad
9. Spring-pad
10. Caliper carrier

REAR DISC BRAKES / 39
LUBRICATION POINTS
T
AF
R
DOINC35AR11005
Symbol Description
D
Grease:Repair kit grease
Brake fluid:DOT3 or DOT4

A Repair kit grease
B Caution
The piston seal and boot kit are coated with special grease . Do
not wipe this grease off.
C Brake fluid:DOT3 or DOT4

/ 40 REAR DISC BRAKE
REAR DISC BRAKE WCH35ASPROC11008

REAR DISC BRAKE REMOVAL
1. Remove 2 pieces bolt mounting bracket
Symbol Decription
A Brake caliper assy
CAUTION
(1) Be sure to tie the cord of the disc brake
assembly
(2) Remove , lock pin ,lift caliper assembly
and retain with wires.
T
AF
DOINC35AR11006
2. Remove tapping bolt from disc brake and

remove rear disc brake shown in illustration.
R
Symbol Decription
B Rear disc brake
D
DOINC35AR11007

REAR DISC BRAKE / 41
REAR BRAKE PAD REMOVAL

1. Release parking brake cable
Symbol Decription
C Parking brake cable
DOINC35AR11008
2. Remove caliper assy bolt (Common ring -

13in,15out)
Symbol Decription
D Common ring 13 inci
E Common ring 15inci
T
AF
DOINC35AR11009
3. Remove brake caliper assy
Symbol Decription
R
F Caliper assy

D
BRAKE PAD ASSY INSTALLATION (RHS REAR

BRAKE)
1. Use Brake Piston retractor tool set below to
rotate the RHS Rear brake piston.
DOINC35AR11010
2. Assemble the special tool as per illustration

given.
Symbol Tool No Tool Name

Brake piston retract-
EZT or (RHS shaft)
A
0010–1R Brake piston retract-
or (RHS slot)
EZT 0010– Brake piston retract-
B
3 or (Plate)
EZT 0057 Brake piston retract-
C
DOIHC35BR05024
or (Adaptor)

/ 42 REAR DISC BRAKE
3. Ensure D is closely touched with E.

4. Grip the special slot.
5. Use brake piston retractor Tool to rotate in
piston into brake caliper assy in ANTI-
CLOCK–WISE DIRECTION.
6. Install new brake pad assy kit..
Symbol Description
A Ratchet
B Socket Size
C Brake piston Retractor Tool
DOINC35AR11011
D Brake piston Retractor
(Plate)
E Brake caliper Assy (nose
portion)
R Brake Caliper Assy
CAUTION
Piston and piston seal are not serviceable due
T
to safety item. Replacement only by complete
set of caliper assy.
AF
R
D

ABS 35B
Content /1
35B ABS
GENERAL INFORMATION ............................................................ 35B/2
OUTLINE OF CHANGES ............................................................. 35B/2
CONSTRUCTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/2
SERVICE SPECIFICATIONS ............................................................ 35B/2

SPECIFICATIONS ..................................................................... 35B/2
SPECIAL TOOLS ........................................................................ 35B/3
TROUBLESHOOTING .................................................................. 35B/4

ABS WARNING LAMP INSPECTION .............................................. 35B/4
ITEMS INDICATED BY THE ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/4
Check that the ABS warning lamp illuminates as follows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/5
PARKING BRAKE WARNING LAMP .............................................. 35B/5
ITEMS INDICATED BY THE PARKING BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 35B/5
VARIANT CODING ..................................................................... 35B/5

SPECIAL FUNCTION ................................................................. 35B/5
VARIANT CODING ................................................................... 35B/6
ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU) ..............................

REMOVAL AND INSTALLATION ...................................................
T 35B/9
35B/9
AF
REMOVAL SERVICE POINT ......................................................... 35B/10
INSTALLATION SERVICE POINT ................................................... 35B/10
INSTALLATION SERVICE POINT ................................................... 35B/10
WHEEL SPEED SENSOR .............................................................. 35B/11

ON-VEHICLE SERVICE ............................................................... 35B/11
R
REMOVAL SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/11

INSTALLATION SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/12
ON-VEHICLE SERVICE ................................................................. 35B/13

D
WHEEL SPEED SENSOR CHECK ................................................... 35B/13

BRAKE PEDAL CHECK AND ADJUSTMENT ..................................... 35B/14
STOP LAMP SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/15
BRAKE BOOSTER OPERATING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/15
BRAKE FLUID LEVEL SENSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/16
BOCSH ABS 9 BRAKE FLUID REPAIR CYCLE WALKTHROUGH .............. 35B/16
BRAKE CYCLE REPAIR PREPARATION STEPS ................................... 35B/17
PADT-II PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/17
BRAKE BLEEDING SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35B/17
HYDRAULIC UNIT BLEED .......................................................... 35B/18

35B ABS
GENERAL INFORMATION WCH35BGINFO12001
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.
T
AF
R
D
DOIQC35BR12002
Symbol Description
1 Hydraulic unit
2 Wheel speed sensor Fr RH / Fr LH
3 ABS rotor Fr RH / Fr LH
4 Stop lamp switch
5 Wheel speed sensor Rr RH / Rr LH
6 ABS rotor Rr RH / Rr LH
7 ABS warning lamp (Integrated in meter combination)
SERVICE SPECIFICATIONS WCH35BSPECS12001
SPECIFICATIONS
Items Standard value / Spec Limit
Wheel speed sensor model Pasline —

ABS 35B
SPECIAL TOOLS /3

Clearance between speed sensor and ABS
1 mm (0.039 in) ± 0.1 mm (0.004 in)
rotor
-40 °C (-40 °F) – 120 °C (248
Hydraulic unit operating temperature —
°F)
-40 °C (-40 °F) – 115 °C (239
Hydraulic unit storage temperature —
°F)
Hydraulic unit voltage operation 13 V ± 3 V —
Hydraulic unit current operation <30 A —
<120 A (Switch - on current
Hydraulic unit current consumption —
peak)
SPECIAL TOOLS WCH35BSTOOL12001
TOOLS
EZT0047
T
interface (VCI)
AF
DOIMC35BR11039

R
CD
DOIMC35BR11042
D

connector; 1 m) VCI
DOIMC35BR11041

USB cable (1.8 m)
PC and VCI
DOIMC35BR11046

35B ABS
/4 TROUBLESHOOTING

DOIMC35BR11045

Ethernet cable
ing to VCI
DOIMC35BR11040

Cable keeper
T
cable messy
DOIMC35BR11043
AF
R
DOIMC35BR11044
D
DOIMC35BR11047
TROUBLESHOOTING WCH35BTSHOT12001
ABS WARNING LAMP INSPECTION

Among the self-diagnos items, an ABS warning
lamp turns 'ON' to notifty the driver that the ABS
system is operational or when an irregularity in
ABS system is detected.
Symbol Description
A ABS warning lamp
ITEMS INDICATED BY THE ABS WARNING LAMP
DOINC35BR09041 The ABS warning lamp indicates.
• ABS system faulty.
• ABS in Special Function / Actuator Function

ABS 35B
VARIANT CODING /5
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 .
T • Electronic Brake Distribution (EBD) mode

failure.
AF
Symbol Description
B Parking brake warning lamp
VARIANT CODING WCH35BSPROC12005
SPECIAL FUNCTION
R
Carry out special function procedure using PADT-

II according to the instruction below;
Special func- Purpose Time of execution

D
tion
Variant cod- To set vehicle When replace
ing variant new hydraulic
unit.
NOTE
Ensure that the model name coded in EMS system
is correct prior to this procedure. Refer to Group
11A, PADT-II Communication, Model Name Read
and Write (WCH11ASPROC12031).

35B ABS
/6 VARIANT CODING
VARIANT CODING
T
AF
R
DOIMC35BR11049
1. Run the PADT-II program and select the

vehicle model ‘Saga FLX’.
D

diagnosis activities.
Symbol Description
A Test selection ‘ Active
Tests’
B Subsystem selection ‘Se-
lect Subsystem’
C System selection ‘BOSCH-
ESP9’

ABS 35B
VARIANT CODING /7
T
AF
DOIMC35BR12001
R
2. Then select the special menu function to start

the bleeding process.
Symbol Description
D
D Function selection ‘Spe-

cial function’
E Test selection ‘Variant
Coding’
Press next to proceed.
DOIMC35BR11078

35B ABS
/8 VARIANT CODING
4. Select the correct vehicle variant through the

drop down button menu.
Then select next to proceed.
DOIMC35BR11079
5. Reconfirm the vehicle variant selected is

correct.
Then select exit button to finish.
T
AF
DOIMC35BR11080
R
D

ABS 35B
ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU) /9
ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU) WCH35BSASSY12001
T
AF
R
DOIQC35BR12001
D
• Brake fluid draining.
• Brake line bleeding.
• Brake pedal adjustment.
Removal steps
1. ABS-ECU connector 9. Electronic Hydraulic Control Unit (EHCU)
2. 10. Nut 10m
Brake pipe connection RL
3. 11. Washer
Brake pipe connection FR
4. 12. Damper rubber
Brake pipe connection FL
5. 13. Clip 5 way
Brake pipe connection RR
6. 14. Clip 2 way
Brake pipe connection MC1
7. 15. Clip 3 way
8. 16. Connector assy
Bracket assy
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

35B ABS
/ 10 ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU)
REMOVAL SERVICE POINT WCH35BSPROC12006
HYDRAULIC UNIT ASSEMBLY REMOVAL

CAUTION
(1) The hydraulic unit assembly is heavy and be
carefully during removal.
(2) The hydraulic unit assembly cannot be disas-
sembled.
(3) The hydraulic unit assembly must not be
dropped or otherwise subjected to impact
shocks.
turned upside down or laid on its side.
BRAKE PIPE CONNECTION
Connect the pipes to the hydraulic unit assembly
T Symbol
1
2
Description
To w/cylinder (FR)
To w/cylinder (RL)
AF
3 To w/cylinder (RR)
4 From the master cylinder (Secondary)
DOIQC35BR12003
5 From the master cylinder (Primary)
A Hydraulic unit ( EHCU)
R

D
CAUTION
(1) The hydraulic unit assembly is heavy and be carefully during removal.
(2) The hydraulic unit assembly cannot be disassembled.
(3) The hydraulic unit assembly must not be dropped or otherwise subjected to impact shocks.
(4) The hydraulic unit assembly must not be turned upside down or laid on its side.
ABS CONNECTOR
Connector ABS to the hydraulic unit assembly as
Symbol Description
A Push Lock connector
B Pull – up lever
DOIMC35BR11008

ABS 35B
WHEEL SPEED SENSOR / 11
DOIMC35BR11009
WHEEL SPEED SENSOR WCH35BSPROC12008
ON-VEHICLE SERVICE
FRONT SPEED SENSOR / REAR SPEED SENSOR
T
REMOVAL
CAUTION
Be careful when handling the pole piece (PP) at
AF
the tip of the speed sensor and the rotor teeth.
Do not damage the components by striking it
against the metal parts.
Symbol Description
A Front axle portion
R
B Rear axle portion

C Front speed sensor
D Rear speed sensor
D
PP Pole piece
T1: 0.5 ± 0.1 kgm (5 ± 1 Nm, 3.62 ± 0.72 ft.lbs)
DOIMC35BR10006

35B ABS
/ 12 WHEEL SPEED SENSOR
FRONT SPEED SENSOR / REAR SPEED

SENSOR INSTALLATION
FRONT SPEED SENSOR INSTALLATION
CAUTION
Be careful the pole piece (PP) at the end of the
speed sensor and the toothed edge of the rotor.
Ensure that the wheel speed sensor is free from
any particle, dirt or dust. Gently wipe the tip of
the sensor with a clean cloth.
Insert a thickness gauge into the space between
the speed sensor's pole piece and the rotor's
toothed surface. Then, tighten the speed sensor
bracket at the position where the clearance is
the standard value all around.
Standard value (C):
T
1.0 ± 0.1 mm (0.039 ± 0.004 in)
Symbol Description
AF
A Front sensor
B Front rotor
DOIMC35BR10004 C 1.0 ± 0.1 mm (0.039 ± 0.004 in)
E ABS front sensor
R
D

ABS 35B
REAR SPEED SENSOR INSTALLATION

CAUTION
Standard value (C):
1.0 ± 0.1 mm (0.039 ± 0.004 in)
Symbol Description
A Rear sensor
T B
C
Rear rotor
1.0 ± 0.1 mm (0.039 ± 0.004 in)
AF
F ABS rear sensor
DOIMC35BR10005
ON-VEHICLE SERVICE WCH35BSPROC12009
WHEEL SPEED SENSOR CHECK

R
CAUTION
D

ent.
Symbol Description
A Wheel speed sensor
DOIMC35BR11014
B Wheel speed sensor harness con-
nector (A-40, A-39 ,E-21, E-20)
C ABS ECU
D ABS ECU harness connector (A-41)

35B ABS
1. Remove the wheel speed sensor.

2. Disconnect the ABS ECU connector.
3. Check at the harness side;
Connect- Pin terminal Description

or
A-41 8 and 19 Wheel speed
sensor Front LH
Condition: Ignition switch ON
1. Continuity check, OK: continuity
2. Short circuit (to ground/battery), OK: no
short circuit
DOIMC35BR11015 NO GOOD: Check the wiring harness. If
problem still exist, replace wheel speed
sensor. If all test fail, replace ABS ECU.
4. Repeat test for other wheel speed sensor
Pin terminal Description

Wheel speed sensor
4 and 16
Front RH
T 17 and 29
Wheel speed sensor Rear
RH
AF
31 and 18
LH

WCH35BSPROC12010

R
Symbol Description
D
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).

nector.
obtained.
Symbol Description
A Pedal down
B Pedal up
C Lock nut
DOIIC35AR9006

ABS 35B

operating rod.
firmly.)
switch.
2. Start the engine, depress the brake pedal
ance between the brake pedal and the floor
board.
Standard :
T check for air trapped in the brake line,

AF
DOIIC35AR9009 and replace defective parts as required.
pushed in the and when it is released. The stop
R
lamp switch is in good condition if there is no

continuity when the plunger is pushed in to a
depth of within 4 mm (0.16 in) from the outer
case edge surface, and if there is continuity when
D
it is released
Symbol Description
DOIIC35AR9010
A 4 mm (0.16 in)
B No continuity
C Continuity
then stop it
Symbol Description
DOIIC35AR9011
A Good

35B ABS
Symbol Description
B No good
2. With the engine stopped, step on the brake
pedal several times.
engine
Symbol Description
DOIIC35AR9012
T If the above tests are okay, the booster per-

of the above three test is not okay at last ,
AF
the check valve , vacuum hose or booster will
be defective.

The brake fluid sensor is in good condition if
there is no continuity when the float surface is
R
above “MIN” and if there is continuity when the

float surface is below “MIN”.
Symbol Description
D
A “MIN”
BOCSH ABS 9 BRAKE FLUID REPAIR CYCLE

WALKTHROUGH WCH35BSPROC12011
DOIIC35AR9016
CAUTION
Always start brake cycle repair with wheel brake
bleed . If result is unsatisfactory, proceed to hy-
draulic unit bleed. This is to avoid the hydraulic
unit from being damaged / overheated.
The vehicle and items should be prepared at the
following condition before carrying out the
brake fluid repair cycle:-
• Engine running / Ignition on.
• Ensure that there is no leakage around the
brake fluid distribution.

ABS 35B
• Use the specified brake fluid , avoid using a

mixture of the specified brake fluid with
other fluid.
• Use transparent bleeder hose and bleeder
bottle.
BRAKE CYCLE REPAIR PREPARATION
STEPS
PADT-II PREPARATION
Set up the PADT-II connection to the vehicle
diagnosis connector.
Symbol Description
A PADT-II vehicle communica-
tion interface (VCI)
B OBD-II cable
C USB cable
DOIMC35BR11048
BRAKE BLEEDING SET UP
T
NOTE
Follow the PADT-II instruction during hydraulic
bleeding procedure. Remove the bleeder screw
to release the brake fluid every the bleeding
AF
cycle starting from RR, FR, FL and end with RL.
1. Remove the caps of the bleeder screw.
Symbol Description
A Cap
R
D
DOIMC35BR11077
2. Connect the transparent bleeder hose of the

transparent bleeder bottle to the bleeder
screw (front axle RH/LH and rear axle RH/LH).
Symbol Description
A Transparent bleeder hose
B Transparent bleeder
bottle
C Bleeder screw
DOIMC35BR11076

35B ABS
NOTE
Always pay attention to the reservoir level during
the entire bleeding procedure. Refill when neces-
sary.
HYDRAULIC UNIT BLEED WCH35BSPROC12012
CAUTION
DOIMC35BR11075 Prepare the brake repair set-up and the PADT-II
VCI connection to the vehicle diagnosis connector
(refer to WCH35BSPROC12003).
NOTE:
BEFORE PROCEEDING, ENSURE THAT
• Ignition On.
• Brake fluid reservoir tank is always at maximum
level.
T • Air conditioning is switch “OFF”.

• In case of communication with PADT-II is inter-
rupted, repeat the bleeding process from the
AF
beginning. Wait for 5 minutes before repeating
the process to avoid the hydraulic motor from
overheated.
Start the process. PADT–II will instruct to open
the bleeder screws as following sequence.
R
Symbol Description
1 Rear (LH)
2 Front (LH)
D
3 Front (RH)
4 Rear (RH)
DOIMC35BR11074

ABS 35B
T
AF
DOIMC35BR11049
R

D
Symbol Description
Tests’
lect Subsystem’
ESP9’

35B ABS
T
AF
DOIMC35BR11059
R

Symbol Description
D

cial function’
E Test selection ‘HCU Re-
pair Bleed ESC’
DOIMC35BR11060

ABS 35B
4. Start bleed cycle by opening the bleeder

screw Rear Left. Then select next to proceed.
DOIMC35BR11061
5. The bleeding process for Rear Left cycle is

now in progress. Check the ‘Routine status:
RUNNING’
NOTE
Ensure to stroke the brake pedal twice a
second and pay attention to the reservoir
T
level during the entire bleeding procedure.
AF
DOIMC35BR11062

now completed. Press the brake pedal
steadily and firmly, and close the bleed screw
R
until there is foamless and bubble free brake

fluid seen at the bleed screw.
Press next to proceed to next the cycle.
D
DOIMC35BR11063
7. Start the cycle by opening the bleeder screw

Front Left. Select next to proceed.
DOIMC35BR11064

35B ABS
8. The bleeding process for Front Left cycle is

RUNNING’
NOTE
DOIMC35BR11065

T
AF
DOIMC35BR11067

Front Right. Select next to proceed.
R
D
DOIMC35BR11068
11. The bleeding process for Front Right cycle is

RUNNING’
NOTE
DOIMC35BR11069

ABS 35B

DOIMC35BR11070

Rear Right. Select next to proceed.
T
AF
DOIMC35BR11071
14. The bleeding process for Rear Right cycle is

RUNNING’
R
NOTE
D
DOIMC35BR11069

Press next to proceed to continue.
DOIMC35BR11072

35B ABS
16. The bleeding process is finish. Press Cancel

button to exit after reading the test result.
DOIMC35BR11073
Check the following conditions;

• Brake not spongy or brake pedal distance is
acceptable .
• No bubble in bleeder hose.
• Pedal free play according to specification.
If result is unsatisfactory, repeat bleeding
process. Always wait for 5 minutes before
T repeating the bleeding process.
Symbol Description
AF
A Bubble
R
D
DOICC035R08053

ESC 35C
Content /1
35C ESC
GENERAL INFORMATION ............................................................ 35C/4
OUTLINE OF CHANGES ............................................................. 35C/4
CONSTRUCTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/4
SERVICE SPECIFICATIONS ............................................................ 35C/5

SPECIFICATIONS ..................................................................... 35C/5
SPECIAL TOOLS ........................................................................ 35C/6
TROUBLESHOOTING .................................................................. 35C/7

STANDARD FLOW OF DIAGNOSTIC ............................................. 35C/7
TROUBLESHOOTING GUIDE ....................................................... 35C/8
NOTES WITH REGARD TO DIAGNOSIS .......................................... 35C/8
Noise, Vibration and Harshness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/8
Sponge Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/9
Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/9
PRECAUTIONS FOR DIAGNOSIS ................................................. 35C/9
DIAGNOSIS FUNCTION ............................................................. 35C/10
DIAGNOSIS CODES CHECK USING PADT - II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/10
T
ABS/ESC SELF TEST .................................................................. 35C/10
ESC WARNING LAMP INSPECTION ............................................... 35C/11
ABS WARNING LAMP INSPECTION .............................................. 35C/11
AF
ITEMS INDICATED BY THE ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/11
Check that the ABS warning lamp illuminates as follows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/11
PARKING BRAKE WARNING LAMP .............................................. 35C/12
ITEMS INDICATED BY THE PARKING BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 35C/12
PROBLEM DIAGNOSIS CONTENT CHART ....................................... 35C/12
INSPECTION CHART FOR DIAGNOSIS CODE. ................................... 35C/21
INSPECTION PROCEDURE FOR DIAGNOSIS CODES .......................... 35C/22
R
CAN COMMUNICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/22

PRIVATE HIGH SPEED CAN COMMUNICATION BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/24
LOST COMMUNICATION WITH ENGINE ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/26
LOST COMMUNICATION WITH ENGINE TRANSMISSION (TCU) . . . . . . . . . . . . . . . . . . . . . . . . 35C/27
COMMUNICATION WITH ACCELERATION SENSOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/28
D
COMMUNICATION WITH STEERING ANGLE SENSOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 35C/30

INVALID DATA RECEIVED FROM ENGINE ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/32
INVALID DATA RECEIVED FROM TRANSMISSION ECU ( TCU ) . . . . . . . . . . . . . . . . . . . . . . . . . 35C/33
SYSTEM SUPPLY VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/34
CONTROL MODULE PUMP MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/36
WHEEL SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/38
BRAKE PEDAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/40
BRAKE PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/42
STEERING ANGLE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/43
ACCELERATION SENSOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/44
ACCELERATION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/45
ABS/ESC SYSTEM ACTIVE TOO LONG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/47
VALVE RELAY SUPPLY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/48
WHEEL SPEED SENSOR GENERIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/50
WHEEL SPEED SENSOR SWAPPED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/51
VARIANT CODE NOT PROGRAMMED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/52
INSPECTION CHART FOR TROUBLE SYMPTOM ................................ 35C/52
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS ....................... 35C/53
INSPECTION PROCEDURE 1 ........................................................... 35C/53

35C ESC
/2 Content
SERVICE DATA REFERENCE TABLE ................................................. 35C/65

DATA LIST ............................................................................. 35C/65
ACTUATOR TEST REFERENCE TABLE ............................................ 35C/66
ACTUATOR TEST SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/67
CHECK AT ABS/ESC-ECU ........................................................... 35C/67
TERMINAL VOLTAGE CHECK CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/67
RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS . . . 35C/68
INSPECTION PROCEDURE USING AN ANALYZER ................................ 35C/69

WHEEL SPEED SENSOR ............................................................. 35C/69
Analyzer connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/69
Standard Wave Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/70
ALTERNATIVE METHOD- CHECK AT ABS ECU ................................. 35C/70
CAN SIGNAL MEASUREMENT ..................................................... 35C/72
ON-VEHICLE SERVICE ................................................................. 35C/73

BOCSH ABS 9 BRAKE FLUID REPAIR CYCLE WALKTHROUGH .............. 35C/73
BRAKE CYCLE REPAIR PREPARATION STEPS ................................... 35C/73
T
PADT-II PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE BLEEDING SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC UNIT BLEED ..........................................................
35C/73
35C/73
35C/74
AF
CALIBRATION .......................................................................... 35C/81
SPECIAL FUNCTIONS ................................................................ 35C/81
PRE-CAUTION FOR OPERATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/81
STEERING ANGLE SENSOR CALIBRATION ...................................... 35C/81
STEERING ANGLE SENSOR CALIBRATION USING SPECIAL FUNCTION IN PADT-II . . . . . . . 35C/82
R
ACCELERATION SENSOR (Ax) CALIBRATION ................................... 35C/86

ACCELERATION SENSOR CALIBRATION USING SPECIAL FUNCTION IN PADT-II . . . . . . . . . 35C/87
D
ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU) .............................. 35C/90

REMOVAL AND INSTALLATION ................................................... 35C/90
REMOVAL SERVICE POINT ......................................................... 35C/91
INSTALLATION SERVICE POINT ................................................... 35C/91
INSTALLATION SERVICE POINT ................................................... 35C/91
WHEEL SPEED SENSOR .............................................................. 35C/92

ON-VEHICLE SERVICE ............................................................... 35C/94
REMOVAL SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/94
INSTALLATION SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/94
ACCELERATION SENSOR ............................................................. 35C/96

SWITCH CENTER ASSEMBLY ........................................................ 35C/97

REMOVAL AND INSTALLATION .................................................. 35C/97
ON-VEHICLE SERVICE ................................................................. 35C/99

ESC 35C
Content /3
WHEEL SPEED SENSOR CHECK ................................................... 35C/99

BRAKE PEDAL CHECK AND ADJUSTMENT ..................................... 35C/100
STOP LAMP SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/101
BRAKE BOOSTER OPERATING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/101
BRAKE FLUID LEVEL SENSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/102
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35C/102
T
AF
R
D

35C ESC
GENERAL INFORMATION WCH35CGINFO11002
OUTLINE OF CHANGES
Due to the latest of ESC (Electronic Stability Control — integrated with Anti-lock Brake System, Traction
Control and Electronic Brake Distribution), the following service procedures have been established.
• Troubleshooting using PADT-II
• Hydraulic unit removal and installation
• Wheel speed sensor removal and installation
• Multi-axis acceleration sensor removal and installation
• ESC-OFF switch removal and installation
T
AF
R
D
DOIQC35CR11001

ESC 35C
SERVICE SPECIFICATIONS /5
T
AF
DOIQC35CR11002
R
Symbol Description
1 Hydraulic unit
2 Wheel speed sensor Fr RH / Fr LH
D
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)
8 Acceleration sensor module*
9 Steering angle sensor
10 ESC—OFF switch
*NOTE
Acceleration sensor module is a low-G acceleration sensor. It consists of lateral acceleration sensor
and yaw rate sensor.
SERVICE SPECIFICATIONS WCH35CSPECS11001
SPECIFICATIONS
Wheel speed sensor model Pasline —

35C ESC
/6 SPECIAL TOOLS

Clearance between speed sensor and ABS
1 mm (0.039 in) ± 0.1 mm (0.004 in)
rotor
-40 °C (-40 °F) – 120 °C (248
Hydraulic unit operating temperature —
°F)
-40 °C (-40 °F) – 115 °C (239
Hydraulic unit storage temperature —
°F)
Hydraulic unit voltage operation 13 V ± 3 V —
Hydraulic unit current operation <30 A —
<120 A (Switch - on current
Hydraulic unit current consumption —
peak)
SPECIAL TOOLS WCH35CSTOOL11001
TOOLS
EZT0047
T
interface (VCI)
AF
DOIQC35CR11003

R
CD
DOIQC35CR11006
D

connector; 1 m) VCI
DOIQC35CR11005

USB cable (1.8 m)
PC and VCI
DOIQC35CR11010

ESC 35C
TROUBLESHOOTING /7

DOIQC35CR11009

Ethernet cable
ing to VCI
DOIQC35CR11004

Cable keeper
T
cable messy
DOIQC35CR11007
AF
R
DOIQC35CR11008
D
DOIQC35CR11011
TROUBLESHOOTING WCH35CSHOOT11041
STANDARD FLOW OF DIAGNOSTIC

Refer to GROUP 000– How to use troubleshooting inspection service points

35C ESC
/8 TROUBLESHOOTING
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-
T NOTE
is Code on page 35C/21 )
AF
• Do not dismantle the control unit from the
modulator. Warranty will be void.
• Improper diagnose without failure code and
DOIQC35CR11012
failure code clearing process will result in claim
rejection.
NOTES WITH REGARD TO DIAGNOSIS
R
The phenomenon listed in the following table are not abnormal.
Phenomenon Explanation of phenomenon

D
When starting the engine, a thudding sound can sometimes be heard coming
System Check sound from inside the engine compartment, but this is because the system operation
check is being performed an is not an abnormal.
1. Sound of the motor inside the ABS hydraulic unit operation (whine).
2. Sound is the generated along with the vibration of the brake pedal.
ABS operation sound 3. When ABS operates, sound is generated from the vehicle chassis due to
repeated brake application and release. (Thump: suspension; squeak:
tires)
For road surfaces such as snow-covered and gravel roads, the braking distance
ABS operation (Long for vehicles with ABS can sometimes be longer than that for other vehicles.
braking distance) Accordingly, advise the customer to drive safely on such roads by lowering
the vehicle speed and not being too overconfident.
Diagnosis detection condition can vary depending on the diagnosis code. Make sure that checking
requirements listed in the ”Comment” are satisfied when checking the trouble symptom again.
Noise, Vibration and Harshness
ABS systems can make loud noise whilst in operation during heavy braking operation. The level of
noise experienced in one vehicle may be higher than in another, but this does not necessarily indicate
a fault with the noisier vehicle.
Typical sources of noise are:

ESC 35C
TROUBLESHOOTING /9
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.
Typical instances are:
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.
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.
The nature of traction control systems also means that a certain level of vibration and harshness will
be felt during a traction control acceleration. The severity is very much dependent on the traction
between the road surface and tyres.
T
Engine Power Reduction - ignition and fuel injection reduction will occur during ESC operation. The
driver may hear a change in engine sound.
AF
Vehicle Surging - Engine torque is being increased and decreased independently of the accelerator
pedal during ESC operation, and is dependent upon drive wheel adhesion. Under some circumstances
surging may be felt by the driver and passengers as the ESC attempts to make the best use of the
traction available.
Sponge Brake Pedal
This symptom should be treated in exactly the same way as it is for non-ABS vehicles. Check the brake
R
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
D
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.
PRECAUTIONS FOR DIAGNOSIS
1. ESC controls brake pressure by the assistance of ECU. The symptoms described in the chart below
may occur during the normal ESC operation, and they do not indicate any sign of malfunction.
Symptoms Description
• When the ESC operates, the operating noise is generated
from the motor (Squeak noise)
These noises are generated when the
• Noise is generated from the brake pedal together with
system and brake pedal operate
the vibration (Gride noise)
normally, and they do not indicate
• When ABS operates, the system repeats the activation
any sign of malfunction.
and deactivation. At this time, the noise is generated from
the chassis components. (Clonk: Suspension, Squeaky: Tyres)

35C ESC
Symptoms Description
This noise is generated when the
system operation check (startup
• A slight shock may be felt when depressing the brake
check performed at the vehicle speed
pedal lightly during the low speed driving.
which is a few km/h higher than the
• Small clicking noise may be heard from the engine com-
predetermined vehicle speed) is per-
partment
formed, and it does not indicate
malfunction.
2. On the snowy or gravelled roads, a vehicle with ABS would have longer braking distance compared
to the one without ABS. Considering this characteristics, advise the customer to drive the vehicle
safely at lower speed and not to put too much confidence in the ABS system when driving on the
above-mentioned roads.
3. The diagnosis code detection condition depends on each diagnosis code. When the trouble
symptoms are rechecked, conditions described in the description for the diagnosis code procedures
should be met.
DIAGNOSIS FUNCTION
DIAGNOSIS CODES CHECK USING PADT - II
Connect the PADT– II to diagnosis connector
T (16–pin), as shown in the illustration.
Symbol Description
AF
A PADT – II vehicle communica-
tion interface ( VCI )
B OBD-II cable
C USB cable
DOIQC35CR11022 CAUTION
Turn the ignition switch off before connecting
R
or disconnecting the PADT- II.

ERASING DIAGNOSIS CODES
Refer to GROUP-000 – How to use troubleshoot-
D
ing inspection service points

ABS/ESC SELF TEST
When the vehicle is started, the ABS/ESC 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
electronic 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.

ESC 35C
ESC WARNING LAMP INSPECTION

WCH35CSHOOT11042
Among the self-diagnose items, an ESC warning

lamp turns 'ON' to notify the driver that the ESC
ESC system is detected.
Symbol Description
A ESC-OFF indicator lamp (Amber)
B ESC indicator lamp (Amber)
DOIQC35CR11015
ITEMS INDICATED BY THE INDICATOR LAMP

INDICATOR LAMP CONDITION DESCRIPTION
ESC switch (at instrument panel) is switched on — ESC is deactivated
ON
ESC-OFF or OFF mode.
OFF ESC switch (at instrument panel) is switched off — ESC in ON mode.
T
Indicator ON for 3 seconds during starting — system in pre-check
ON mode.
ESC Indicator ON continuously — ESC system malfunction.
AF
OFF ESC system is in good condition.
Blinking ESC is active. Indicator blinking 2 times per second (2Hz).
Check that the ESC indicator lamp illuminates as follows.
1. When the ignition key is turn to “ON”, the ESC warning lamp illuminates for approximately 3
seconds and then switches off.
R
2. When the ignition key is turned to “START”, the ESC warning lamp remains switched off.
3. When the ignition key is turn from “START” back to “ON” the ABS warning lamp illuminates for
approximately 3 seconds and then stays switch off
4. If the illumination is other than the above, check the diagnosis codes.
D
ABS WARNING LAMP INSPECTION

Among the self-diagnos items, an ABS warning
lamp turns 'ON' to notifty the driver that the ABS
ABS system is detected.
Symbol Description
A ABS warning lamp
ITEMS INDICATED BY THE ABS WARNING LAMP
The ABS warning lamp indicates.
• ABS system faulty.
DOIQC35CR11013
• 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.

35C ESC
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
PROBLEM DIAGNOSIS CONTENT CHART

DOIQC35CR11014
T
AF
WCH35CSHOOT11043
DIAGNOSIS CON- INDICATOR LAMP

CODE PADT- II DISPLAY PROBABLE CAUSE
TENT EBD ABS ESC
1) Short circuit between CAN
+ and CAN-
Bus off 2) Short circuit between CAN
R
High Speed CAN + and UBATT

U0001 Communication 3) Heavy bus disturbance - - -
Bus Circuit voltage be- Supply voltage is below full
D
low threshold functional voltage threshold

Circuit voltage Supply voltage is above full
above threshold functional voltage threshold
1) Short circuit between CAN
+ and CAN-
Bus off 2) Short circuit between CAN
Private High + and Ubatt
U0601 Speed CAN Com- 3) Heavy bus disturbance - - ON
munication Bus Circuit voltage be- Supply voltage is below full
low threshold functional voltage threshold
Circuit voltage Supply voltage is above full
Lost Communica-
no sub type inform- Data not received from EMS
U0100 tion With - - ON
ation module.
ECM/PCM
Lost Communica- no sub type inform- Data not received from TCU
U0101 - - ON
tion with TCM ation module

ESC 35C

TENT EBD ABS ESC
Lost Communica-
tion with Acceler- no sub type inform- Data not received from Accel-
U0125 - - ON
ation Sensor ation eration Sensor module
Module
Lost Communica-
tion With Steer- no sub type inform- Data not received from SAS
U0126 - - ON
ing Angle Sensor ation module
Module
1) Invalid Pedal Position
Invalid Data Re-
no sub type inform- 2) Invalid Motor Torque
U0401 ceived from - - ON
ation 3) Invalid Motor RPM
ECM/PCM
4) Invalid Throttle Position
Invalid Data Re- no sub type inform- Invalid Checksums or Rolling
U0402 - - ON
ceived from TCM ation Counters received from TCU
Internal status bits or data
Internal Electronic
from Acceleration Sensor are
Failure
invalid
Invalid Data Re- Signal Invalid

ceived From Accel-
T
Internal signal bits from Accel-
eration Sensor are invalid
AF
U0432 Invalid Checksum received - - ON
eration Sensor General Checksum
Module from Acceleration Sensor
Failure
module
Invalid Rolling Counter re-
Missing Message ceived from Acceleration
Sensor
R
1) Failed status received from

Internal Electronic SAS module
Failure 2) Invalid Offset received
Invalid Data Re- from SAS module
D
ceived From Invalid Steering Angle re-

U0428 Signal Invalid - - ON
Steering Angle ceived from SAS module
Sensor Module General Checksum Invalid Checksum received
Failure from SAS module
Invalid Rolling Counter re-
Missing Message
ceived from SAS module
General Electrical General Electrical Faults. Mi-
ON ON ON
ABS/ESC Control Failure crocontroller is faulty.
U3000
Module Watchdog/safety uc Watchdog timeout detection.
- ON ON
Failure Microcontroller is faulty.
Circuit voltage be- Supply voltage is below full
ABS/ESC System low threshold functional voltage threshold
U3003 ON ON ON
Voltage Circuit voltage Supply voltage is above full

35C ESC

TENT EBD ABS ESC
Switch Control Internal valve related failure
C0001
Valve (USV) 1 has been detected.
Switch Control Internal valve related failure
C0002
Valve (USV) 2 Internal electronic has been detected.
ON ON ON
Priming Control failure Internal valve related failure
C0003
Valve (HSV) 1 has been detected.
Priming Control Internal valve related failure
C0004
Valve (HSV) 2 has been detected.
Left Front Inlet
C0010
Control Valve
Left Front Outlet
C0011
Control Valve
Right Front Inlet
C0014
Control Valve
Right Front Out-
C0015
let Control Valve Internal electronic Internal valve related failure
T
ON ON ON
Left Rear Inlet failure has been detected.
C0018
Control Valve
AF
Left Rear Outlet
C0019
Control Valve
Right Rear Inlet
C001C
Control Valve
Right Rear Outlet
C001D
Control Valve
R
1) Motor failure (e.g.

Circuit short to
blocked)
ground
2) ADC failures.
Circuit short to bat-
D
Leaking Motor Relay

tery
ABS/ESC Pump
C0020 Circuit voltage be- Interruption or under voltage - ON ON
Motor Control
low threshold at UBMR
Internal electronic
Failure on the motor relay.
failure
RFP mechanical clamp, pos-
Actuator stuck
sibly worn out brushes

ESC 35C

TENT EBD ABS ESC
1) Short circuit WSS supply
line to UBATT.
2) Short circuit WSS to anoth-
er WSS.
General Electrical 3) Short circuit WSS supply
Failure line or sensor line to GND.
4) Short circuit WSS sensor
line to UBATT.
5) Interruption of WSS supply
line or sensor line.
1) Open circuit in the WSS
Left Front Wheel line
C0031 - ON ON
Speed Sensor 2) Short circuit to UZ in the
WSS line
3) Short circuit to GND in
WSS line
Signal plausibility 4) WSS dislodging from
T
failure bracket
5) Input amplifier in ECU
faulty
AF
6) Tooth wheel missing
7) WSS not installed
8) Too great air gap between
WSS and tone wheel
WSS_FL line failure (short cir-
Left Front Wheel cuit supply line or sensor line
Circuit short to bat-
C0032 Speed Sensor to GND short circuit sensor - ON ON
R
tery
Supply line to UBATT interruption of
supply line or sensor line).
D

35C ESC

TENT EBD ABS ESC
line to UBATT.
er WSS.
line to UBATT.
Right Front 1) Open circuit in the WSS
C0034 Wheel Speed line - ON ON
Sensor 2) Short circuit to UZ in the
WSS line
WSS line
T
failure bracket
faulty
AF
WSS and tone wheel
WSS_FR line failure (short
circuit supply line or sensor
Right Front
Circuit short to bat- line to GND short circuit
R
C0035 Wheel Speed - ON ON

tery sensor line to UBATT interrup-
Sensor Supply
tion of supply line or sensor
line).
D

ESC 35C

TENT EBD ABS ESC
line to UBATT.
er WSS.
line to UBATT.
Left Rear Wheel line
C0037 - ON ON
WSS line
WSS line
T
failure bracket
faulty
AF
WSS and tone wheel
WSS_RL line failure (short
Left Rear Wheel
R
C0038 Speed Sensor - ON ON

Supply
line).
D

35C ESC

TENT EBD ABS ESC
line to UBATT.
er WSS.
line to UBATT.
Right Rear Wheel line l
C003A - ON ON
WSS line
WSS line
T
failure bracket
faulty
AF
WSS and tone whee
WSS_RR line failure (short
Right Rear Wheel
R
C003B Speed Sensor - ON ON

Supply
line).
D
Circuit short to bat- 1) Interruption of BLS

tery/ground, signal 2) Short BLS to Gnd
Brake Pedal plausibility failure 3) Short BLS to supply
C0040 - - ON
Switch BLS is set while Accelerate is
Signal plausibility
pressed with no pressure in
failure
master cylinder
1) Offset from Pressure
Signal bias level out
sensor is >10bar
of range / zero ad-
2) Pressure sensor sensitivity
justment failure
error >10%
Brake Pressure 1) Interruption of Pressure
C0044 Signal Line - - ON
Sensor
2) Short Ps Signal to Ground
Internal electronic
3) Short Ps Signal to Sensor-
failure
supply
4) Interruption of Sensorsup-
ply to Ps

ESC 35C

TENT EBD ABS ESC
Steering Angle Sensor not
Missing calibration,
Calibrated
Constant angle received from
of range / zero ad-
Steering Angle Sensor
justment failure,
1) Steering Angle offset is
Steering Wheel too high
C0051 2) Gradient received is im- - - ON
Position Sensor
plausible
Signal plausibility 3) Range received is implaus-
failure ible
4) Plausibility vs Yrs is too
high
5) Sign of Steering Angle is
incorrect
Offset for Lateral Accelera-
of range / zero ad-
T
tion is too high
justment failure,
1) Received signal differs
Lateral Accelera- from modelled signal by
AF
C0061 - - ON
tion Sensor 2.5m/s²
Signal plausibility
2) Angle received is implaus-
failure
ible
3) Acceleration received from
sensor is implausible
R
Offset for Yaw Rate is too

of range / zero ad-
high
justment failure,
1) Yaw Rate differs from
D
modelled value by >25%

C0063 Yaw Rate Sensor 2) Plausibility vs SAS is too - - ON
high
Signal plausibility
3) Gradient received is im-
failure
plausible
4) Range received is implaus-
ible
5) Sign of YRS is incorrect
ABS System Act- No sub-type inform- 1) Incorrect tooth count
C106A ON ON ON
ive Too Long ation 2) Permanent bad WSS signal
1) Implausible controller
(VDC) interventions
ESC System Active No sub-type inform- 2) Wrong signal from yaw
C106B - - ON
Too Long ation rate sensor (YRS), steering
angle sensor (SAS) or lateral
acceleration sensor (AYS)

35C ESC

TENT EBD ABS ESC
1) UVR is shorted to ground
Circuit short to
2) Valve driver (Qx) is/are
ground
shorted to ground
1) Defective valve relay (does
not switch OFF)
Circuit short to bat- 2) UVR has a short to UBVR
tery 3) Status of valve relay gate
Valve Relay Sup-
C100A actuation from system ASIC ON ON ON
ply Circuit
is wrong.
1) Defective valve relay (does
not switch OFF)
Internal electronic 2) UVR has a short to UBVR
failure 3) Status of valve relay gate
actuation from system ASIC
is wrong.
Internal electronic General Valve failure has oc-
C100B Valve Generic ON ON ON
failure curred.
Internal electronic
failure
T
Multiple failures or suspected
failures to the WSS have oc-
curred
AF
Multiple;
line
Wheel Speed 2) Short circuit to UZ in the
C103D WSS line ON ON ON
Sensor Generic
Signal compare 3) Short circuit to GND in
R
failure WSS line

4) WSS dislodging from
bracket
D
faulty
Wheel Speed
Wrong Mounting Wheel speed sensors are
C103E Sensor Swapped
Position swapped at front axle.
Front Axle
- ON ON
Wheel Speed
Wrong Mounting Wheel speed sensors are
C103F Sensor Swapped
Position swapped at rear axle.
Rear Axle
Variant Code not pro-
Not programmed,
grammed in ESC ECU
Bus signal/ meas- Variant code not received
sage failure. from ECM/PCM CAN message
C1000 Variant Code ON ON ON
EMS message not received
Missing Message
from ECM/PCM
Incorrect compon- ESC ECU and ECM/PCM EMS
ent installed Variant mismatch

ESC 35C
INSPECTION CHART FOR DIAGNOSIS CODE. WCH35CSHOOT11044
Get an understanding of the problem diagnosis content and check according to the inspection dia-
gnosis chart.
CODE PADT- II DISPLAY REFERENCE PAGE

U0001 High Speed CAN Communication Bus 35C/22
U0601 Private High Speed CAN Communication Bus 35C/24
U0100 Lost Communication With EMS 35C/26
U0101 Lost Communication with TCU 35C/27
U0125 Lost Communication with Acceleration Sensor Module
Invalid Data Received From Acceleration Sensor 35C/28
U0432
Module
Lost Communication With Steering Angle Sensor
U0126
Module
U0140 Lost Communication With Body Control Module 35C/30
Invalid Data Received From Steering Angle Sensor
U0428
Module
U0401 Invalid Data Received from EMS 35C/32
U0402
U3003
T
Invalid Data Received from TCU
ABS/ESC System Voltage
35C/33
35C/34
AF
U3000 ABS/ESC Control Module
C0001 Switch Control Valve (USV) 1
C0002 Switch Control Valve (USV) 2
C0003 Priming Control Valve (HSV) 1
C0004 Priming Control Valve (HSV) 2
R
C0010 Left Front Inlet Control Valve

Replace ABS/ESC ECU (refer
C0011 Left Front Outlet Control Valve
to WCH35CSASSY11054)
C0014 Right Front Inlet Control Valve
D
C0015 Right Front Outlet Control Valve

C0018 Left Rear Inlet Control Valve
C0019 Left Rear Outlet Control Valve
C001C Right Rear Inlet Control Valve
C001D Right Rear Outlet Control Valve
C0020 ABS/ESC Pump Motor Control 35C/38
C0031 Left Front Wheel Speed Sensor
C0032 Left Front Wheel Speed Sensor Supply
C0034 Right Front Wheel Speed Sensor
C0035 Right Front Wheel Speed Sensor Supply
35C/40
C0037 Left Rear Wheel Speed Sensor
C0038 Left Rear Wheel Speed Sensor Supply
C003A Right Rear Wheel Speed Sensor
C003B Right Rear Wheel Speed Sensor Supply
C0040 Brake Pedal Switch 35C/42
C0044 Brake Pressure Sensor 35C/43
C0051 Steering Wheel Position Sensor 35C/44

35C ESC
CODE PADT- II DISPLAY REFERENCE PAGE

C0061 Lateral Acceleration Sensor
35C/45
C0063 Yaw Rate Sensor
C006A Acceleration Sensor 35C/47
C106A ABS System Active Too Long
35C/48
C106B ESC System Active Too Long
C100A Valve Relay Supply Circuit
35C/50
C100B Valve Generic
C103D Wheel Speed Sensor Generic
C103E Wheel Speed Sensor Swapped Front Axle 35C/51
C103F Wheel Speed Sensor Swapped Rear Axle
C1000 Variant Code 35C/52
INSPECTION PROCEDURE FOR DIAGNOSIS CODES WCH35CSHOOT11045
CAN COMMUNICATION
PADT Display Probable Causes
Code No.U0001 : CAN Communication
T •
Code number are output if the ABS/ESC-ECU detects an open- •
Malfunction of EMS system.
CAN communication problem
AF
circuit or short-circuit in the CAN communication wire. • CAN communication problem with
EMS system
R
D

ESC 35C
T
AF
DOIQC35CR11016
R
D

35C ESC
T
AF
DOIQC35CR11017
R
PRIVATE HIGH SPEED CAN COMMUNICATION BUS WCH35CSHOOT11046
PADT-II Display Probable Causes

Code No.U0601 – Private High Speed Can Communication Bus
D
• Open/short circuit to steering

ABS/ESC – ECU detects abnormality in private high speed can angle sensor/acceleration sensor
communication bus for acceleration sensor module and module.
steering angle sensor. • Private can communication failure

ESC 35C
T
AF
DOIQC35CR11021
R
D

35C ESC
T
AF
DOIQC35CR11020
R
LOST COMMUNICATION WITH ENGINE ECU WCH35CSHOOT11047

Code No.U0100 – Lost Communication With EMS
D
• Fault in EMS system

ABS/ESC – ECU unable to communicate with engine ECU. • Engine ECU malfunction
• Communication fault

ESC 35C
T
AF
DOIQC35CR11023
LOST COMMUNICATION WITH ENGINE TRANSMISSION (TCU) WCH35CSHOOT11048

R

Code No.U0101 – Lost Communication With TCU
• Fault in TCU system.
• Engine TCU malfuntion.
D
ABS/ESC – ECU unable to communicate with engine TCU.

• Communications fault.

35C ESC
T
AF
DOIQC35CR11024
COMMUNICATION WITH ACCELERATION SENSOR MODULE WCH35CSHOOT11049

R

Code No.U0125 – Lost Communication With Acceleration sensor module
Code No.U0432 – Invalid Data Received From Acceleration sensor module
• Open/short circuit to acceleration
D
ABS/ESC – ECU unable to communicate with acceleration sensor sensor module (Yaw rate sensor).
module (Yaw rate sensor). • Private CAN communication fail-
ure

ESC 35C
T
AF
DOIQC35CR11025
R
D

35C ESC
T
AF
DOIQC35CR11026
R
COMMUNICATION WITH STEERING ANGLE SENSOR MODULE WCH35CSHOOT11050

Code No.U0126 – Lost Communication With Steering Angle Sensor Module
D
Code No.U0428 – Invalid Data Received From Steering Angle Sensor Module
• Open/short circuit to steering
ABS/ESC—ECU unable to communicate with steering angle angle sensor.
sensor. • Private CAN communication fail-
ure

ESC 35C
T
AF
DOIQC35CR11027
R
D

35C ESC
T
AF
DOIQC35CR11028
R
INVALID DATA RECEIVED FROM ENGINE ECU WCH35CSHOOT11051

Code No.U0401 – Invalid Data Received From EMS
D
• Fault in EMS system.

ABS/ESC – ECU detects fault from engine ECU. • Engine ECU malfuntion.
• CAN communications fault.

ESC 35C
T
AF
DOIQC35CR11029
INVALID DATA RECEIVED FROM TRANSMISSION ECU ( TCU ) WCH35CSHOOT11052

R

Code No.U0402 – Invalid Data Received From TCU
• Fault in engine transmission sys-
tem.
D
ABS/ESC – ECU detects fault from transmission TCU • TCU malfunction.

• CAN communication fault.

35C ESC
T
AF
DOIQC35CR11030
SYSTEM SUPPLY VOLTAGE WCH35CSHOOT11053

R

Code No.C3003 – ABS/ESC System Supply Voltage.
• Blown fuse.
This code is output if the ABS/ESC-ECU power supply voltage • Battery voltage too low, below
D
drops below or rises above the rated values. operating value.

Furthermore, if the voltage return to normal, this code is no • Malfunction of wiring harness or
longer output. connector.
• Malfunction of hydraulic unit.
CAUTION
Before carrying out the following inspection, check the battery level, and recharge it if necessary.

ESC 35C
T
AF
DOIQC35CR11031
R
D

35C ESC
T
AF
DOIQC35CR11032
R
CONTROL MODULE PUMP MOTOR WCH35CSHOOT11054

Code No.C0020 – ABS/ESC Pump Motor Control.
D
• Pump motor power connector

(pin1) open/short circuit
• Pump motor GND connection
The ABS/ESC – ECU detects open / short circuit at the control (connector pin13) open / short
module pump motor. circuit.
• Internal electronic failure
• Actuator stuck

ESC 35C
T
AF
DOIQC35CR11033
R
D

35C ESC
T
AF
DOIQC35CR11034
R
WHEEL SPEED SENSOR WCH35CSHOOT11055

Code No.C0031 , C0032 , C0034 , C0035 , C0037 , C0038 , C003A and C003B .
D
• Malfunction of wheel speed

Code No.C0031 , C0032 , C0034 , C0035 , C0037 , C0038 , C003A sensor.
and C003B are output if the ABS/ESC-ECU detects an open • Malfunction of wiring harness or
circuit or short-circuit in the (+) wire or (-) wire in any one of connector
the four wheel speed sensors. • Malfunction of ABS rotor.
• When there is no input from any one the four wheel speed • Too much gap between the sensor
sensors when travelling at several km/h or more, even and the rotor
though open circuit can not be verified. • Malfunction of hydraulic unit.
• Malfunction of wheel bearing

ESC 35C
T
AF
DOIQC35CR11035
R
D

35C ESC
T
AF
R
D
DOIQC35CR11036
BRAKE PEDAL SWITCH WCH35CSHOOT11056

Code No.C0040 – Brake Pedal Switch
• Stop lamp switch failure.
ABS/ESC – ECU detects malfuntion in stop lamp switch. • Open/Short circuit.
• Faulty input stage in ECU.

ESC 35C
T
AF
DOIQC35CR11037
R
D

35C ESC
T
AF
DOIQC35CR11042
R
BRAKE PRESSURE SENSOR WCH35CSHOOT11057

Code No.C0044 – Brake Pressure Sensor
D
• ABS/ESC unit has recorded positive hydraulic brake pressure • Signal has level out of range.
with no stop light input. • Zero adjustment failure.
• Stop light input has remained constant for over 1 minute • Internal electronic failure.
without positive hydraulic brake pressure.

ESC 35C
T
AF
DOIQC35CR11038
STEERING ANGLE SENSOR WCH35CSHOOT11058

R

Code No.C0051 – Steering Wheel Position Sensor
• Steering angle sensor out of ad-
D
• Sensor missing calibration,signal bias level out of range. justment.

• Zero adjustment of steering angle sensor. • Steering angle sensor incorrectly
• Signal plausibility failure. fitted.

35C ESC
T
AF
DOIQC35CR11039
ACCELERATION SENSOR MODULE WCH35CSHOOT11059

R

Code No.C0061 – Lateral Acceleration Sensor
Code No.C0063 – Yaw Rate Sensor
• Signal bias level out of range/zero
D
The ABS/ESC – ECU detects abnormality to acceleration sensor adjustment failure.

module components. • Signal plausibility failure

ESC 35C
T
AF
DOIQC35CR11040
ACCELERATION SENSOR WCH35CSHOOT11060

R

Code No.C006A – Acceleration Sensor
• Missing voltage input to accelera-
tion sensor signal.
D
• Open/short circuit to acceleration

The ABS/ESC – ECU detects abnormality to acceleration sensor. sensor.
• Missing earth connection to accel-
eration sensor.

35C ESC
T
AF
DOIQC35CR11041
R
D

ESC 35C
T
AF
DOIQC35CR11043
R
ABS/ESC SYSTEM ACTIVE TOO LONG WCH35CSHOOT11061

Code No.C106A – ABS System Active Too Long
D
Code No.C106B – ESC System Active Too Long

• Incorrect tooth count.
The ABS/ESC – ECU detects the abnormality in wheel speed • Permanent bad wheel speed
sensor. sensor signal.

35C ESC
T
AF
DOIQC35CR11044
R
VALVE RELAY SUPPLY CIRCUIT WCH35CSHOOT11062

Code No.C100A – Valve relay supply circuit
D
Code No.C100B – Valve generic

• Value relay supply circuit (pin 25)
The ABS/ESC – ECU detects open / short circuit at the valve relay open/short circuit.
supply circuit. • Internal electronic failure

ESC 35C
T
AF
DOIQC35CR11045
R
D

35C ESC
T
AF
DOIQC35CR11046
R
WHEEL SPEED SENSOR GENERIC WCH35CSHOOT11063

Code No.C103D – Wheel Speed Sensor Generic
D
• Wheel speed sensor swapped.

ABS/ESC – ECU detects multiple failures or suspected failures • Wheel speed sensor setting incor-
to the wheel speed sensor have occurred. rect.
• Wheel speed sensor malfunction.

ESC 35C
T
AF
DOIQC35CR11047
R
WHEEL SPEED SENSOR SWAPPED WCH35CSHOOT11064

Code No.C103E – Wheel Speed Sensor Swapped – Front Axle
D
Code No.C103F – Wheel Speed Sensor Swapped – Rear Axle

• ABS/ESC-ECU unit detects swapped connection of • Swap connection of Front/Rear
Front/Rear wheel speed sensor by comparing the data re- speed sensor.
ceived from Steering angle sensor and Wheel speed sensor

35C ESC
T
AF
DOIQC35CR11048
VARIANT CODE NOT PROGRAMMED WCH35CSHOOT11065

R

Code No.C1000 – Variant code not programmed
• Incorrect ABS/ESC modulator as-
ABS/ESC – ECU unable to detects communication with vehicle sembly or ECU fitted.
D
system. • Variant code not programmed.
DOIQC35CR11049
INSPECTION CHART FOR TROUBLE SYMPTOM WCH35CSHOOT11066
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.

ESC 35C
Trouble Symptom Inspection procedure No. Reference page

Communica- Communication with all system is not
1 35C/53
tion with possible.
PADT-II is
not pos- Communication with ESC only is not
2 35C/55
sible. possible.
ESC warning display stays ON after the engine is
3 35C/57
started
ESC OFF indicator lamp stays ON after the engine
4 35C/59
is started.
Unequal braking power on both sides
Insufficient braking power
Faulty ESC ABS operates under normal braking
5 35C/61
operation conditions
ABS operates before vehicle stops un-
der normal braking conditions
ESC operates too frequently. 6 35C/63
CAUTION
T
1 - If steering movements are made when driving at high speed, or when driving on road surfaces
with low frictional resistance, or when passing over bumps, the ABS may operate even though
sudden braking is not being applied. Because of this, when getting information from the customer,
AF
check if the problem occurred while driving under such conditions as these.
2 - During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such
phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent
the wheels from locking and is not an abnormality.
3 - During diagnosis, a diagnosis code associated with other system may be set when the ignition
switch is turned on with connector(s) disconnected. On completion, confirm all systems for dia-
R
gnosis code(s). If diagnosis code(s) are set, erase them all.
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS WCH35CSHOOT11067

D
Communication between the PADT- II and the whole
Probable cause
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- II
circuit or the earth of the diagnosis connector. due to high interference
• Battery voltage too low

35C ESC
T
AF
R
D
DOIQC35CR11050

ESC 35C
T
AF
R
D
DOIQC35CR11051
INSPECTION PROCEDURE 2 WCH35CSHOOT11068
Communication between PADT- II is possible.

Probable cause
(Communication with ESC is not possible)
The cause may be an open circuit in the ABS/ESC-ECU • Blown fuse
power circuit or an open circuit in the diagnosis out- • Malfunction of wiring harness or connector
put circuit. • Malfunction of ABS/ESC-ECU

35C ESC
T
AF
R
D
DOIQC35CR11052

ESC 35C
T
AF
R
D
DOIQC35CR11053
When ignition key is turned to “ON” (engine stopped).

Probable cause
ESC indicator lamp does not illuminate.
• Blown fuse
The cause may be an open circuit in the lamp power supply • Burnt out ESC indicator lamp LED di-
circuit, a blown lamp LED diode , an open circuit between ode.
CAN HI and CAN LO wiring harness. • Malfunction of wiring harness or
connector

35C ESC
T
AF
R
D
DOIQC35CR11054

ESC 35C
T
AF
DOIQC35CR11055
R
Even after the engine is started, the ESC indicator

Probable cause
lamp remains illuminated.
D
• Malfunction of combination meter

The cause is probably a short – circuit, in the ESC in- • Malfunction of wiring harness or (short
dicator lamp illumination circuit. circuit)
• Malfunction of hydraulic unit
NOTE
This trouble symptom is limited to cases where communication with the PADT-II is possible (ABS/ESC-
ECU power supply is normal) and the diagnosis code is a normal diagnosis code.

35C ESC
T
AF
R
D
DOIQC35CR11056

ESC 35C
T
AF
DOIQC35CR11057
R
Faulty ESC operation Probable cause

• Improper installation of wheel speed sensor
D
This varies depending on the driving condi- • Malfunction of wiring harness connector
tions and the road surface conditions, so • Foreign material adhering to wheel speed sensor
problem diagnosis is difficult. However, if a • Malfunction of wheel speed sensor
normal diagnosis code is displayed, carry out • Malfunction of rotor
the following inspection. • Malfunction of wheel bearing
• Malfunction of hydraulic unit

35C ESC
T
AF
DOIQC35CR11058
R
D

ESC 35C
T
AF
DOIQC35CR11059
R
ESC operates too frequently Probable cause

• Mounting of wheels and tyres other than with
D
genuine specified size.

Although the cause of the trouble cannot be • Tyre pressure abnormality
clearly resolved since it depends on the run- • Tyre wear and deterioration
ning status and road surface condition, the • Mounting of non-genuine braking device or impact
malfunction of the hydraulic circuit may occur reduction device.
if any diagnosis code is not detected. • Wheel alignment abnormality.
If wheels and tyres other than the ones with • Malfunction of brake related parts.
genuine specified size are mounted, the • Malfunction of the wheel speed sensor.
ABS/ESC may be activated prematurely. • Malfunction of the G and yaw rate sensor.
If a non-genuine braking device or non- • Steering wheel sensor malfunction.
genuine impact reduction device is mounted, • Malfunction of hydraulic unit (integrated with
the ABS/ESC may be activated prematurely. ABS/ESC ECU).
• Malfunction of hydraulic circuit.
• External radio wave noise interference.

35C ESC
T
AF
R
D
DOIQC35CR11060

ESC 35C
SERVICE DATA REFERENCE TABLE / 65
SERVICE DATA REFERENCE TABLE WCH35CSHOOT11073
DATA LIST
• All loads (lamps, electrical cooling fan and accessories should be OFF all the time during the test.
• Let the engine runs for 10 to 15 mins or until the engine temperature reach 80 °C (176 °F) (engine
runs in hot condition)
• When the vehicle is running, there may be delay in ABS ECU data processing. Therefore the data
value displayed may not in real time.
T
AF
R
D

35C ESC
/ 66 SERVICE DATA REFERENCE TABLE
No Dynamic Data Check condition Standard value Remarks

“PADT-II” display is identical
1 Vehicle Speed 0 km/h
to speedometer indication
Front Left Wheel Speed “PADT-II” display is identical
2 0 km/h
Sensor to speedometer indication
Front Right Wheel Speed “ON” when the Rear left ISO
3 0 km/h
Sensor valve is activated
Rear Left Wheel Speed “ON” when the Rear left
4 0 km/h
Sensor DUMP valve is activated
Rear Right Wheel Speed “PADT-II” display is identical
5 0 km/h
Sensor to speedometer indication
6 Battery voltage V System voltage
“ON” when the Rear right
7 Brake Light Switch Status ON/OFF/Faulty
DUMP valve is activated
“ON” when the Front left
8 Pump Motor Status ON/OFF
ISO valve is activated
“ON” when the Front left
9 Front Left Inlet Valve Vehicle Moving ON/OFF
DUMP valve is activated
10 Front Left Outlet Valve

NOTE
When the vehicle is
stationary wheel
T
ON/OFF
“PADT-II” display is identical
to speedometer indication
AF
“ON” when the Front right
11 Front Right Inlet Valve speed reading is 0 ON/OFF
ISO valve is opened
km/h
“ON” when the Front right
12 Front Right Outlet Valve Standard value will ON/OFF
DUMP valve is closed
be based on vehicle
speed. “ON” when power is sup-
13 Rear Left Inlet Valve ON/OFF
plied to valve
R
“ON” when power is sup-

14 Rear Left Outlet Valve ON/OFF
plied to pump motor
“ON” when the Rear right
15 Rear Right Inlet Valve ON/OFF
ISO valve is activated
D
The system will change to

16 Rear Right Outlet Valve ON/OFF Adjust mode only when the
Special Function is conducted
17 Switch Valve 1 (USV1) ON/OFF Switch Valve 1 status
18 Switch Valve 2 (USV2) ON/OFF Switch Valve 2 status
High Pressure Switch High Pressure Switch Valve
19 ON/OFF
Valve 1 (HSV1) 1 status
High Pressure Switch High Pressure Switch Valve
20 ON/OFF
Valve 2 (HSV2) 2 status
Master Cylinder Pressure
21 Master Cylinder Pressure Bars
status
Note:
Inlet valve (normally open valve) is activated when the valve is closed.
Outlet valve (normally closed valve) is activated when the valve is opened.
ACTUATOR TEST REFERENCE TABLE WCH35CSHOOT11074
The PADT-II activates the following actuator for testing.

ESC 35C
SERVICE DATA REFERENCE TABLE / 67
NOTE
1 - Actuator testing is only possible when the vehicle is stationary. If the vehicle speed during actuator
testing exceeds 10 km/h, force actuator will be canceled.
2 - The ABS warning lamp will be ON while actuator test is carried out
ACTUATOR TEST SPECIFICATION
No. Item Remark
Clicking sound can be heard at the valve indicating
1 Pump Motor
pump motor operation
2 Front Left Inlet Valve
3 Front Left Outlet Valve
4 Front Right Inlet Valve
5 Front Right Outlet Valve
6 Rear Left Inlet Valve
7 Rear Left Outlet Valve Clicking sound can be heard at the valve indicating
8 Rear Right Inlet Valve the valve operation
9 Rear Right Outlet Valve
10 Switch Valve 1 (USV1)
11
12
Switch Valve 2 (USV2)
High Pressure Switch Valve 1 (HSV1)
T
AF
13 High Pressure Switch Valve 2 (HSV2)
CHECK AT ABS/ESC-ECU WCH35CSHOOT11075
Remove the harness connector cover and meas-

ure the terminal voltage of the ABS/ESC-ECU at
harness side.
R

1. Measure the voltages between each respect-
ive terminal.
D
The terminal layouts are shown in the illustra-

tions below.
DOIQC35CR11072
Connector terminal
Check item Checking requirements Normal condition
No.
1 Motor relay and ABS/ESC- ECU Always System voltage
Valve relay power and ECU re-
25 Always System voltage
lay
Ignition switch : ON System voltage
28 ABS/ESC- ECU relay
Ignition switch : START 0V
Brake light ON > 9.5 V
30 Brake light input
Brake light OFF <2V
ESC switch ON > 9.5 V
12 ESC switch input
ESC switch OFF <2V

35C ESC
/ 68 SERVICE DATA REFERENCE TABLE
RESISTANCE AND CONTINUITY BETWEEN

HARNESS-SIDE CONNECTOR TERMINALS
1. Turn the ignition switch off and disconnect
the ABS/ESC-ECU connectors before checking
resistance and continuity.
2. Check them between the terminals indicated
in the table below
3. The terminal layouts are shown in the illus-
tration below.
DOIQC35CR11072
Connector terminal No. Signal Normal condition

8 and 19 Front-left wheel speed sensor
31 and 18 Rear left wheel speed sensor
Continuity
17 and 29 Rear right wheel speed sensor
4 and 16 Front-right wheel speed sensor
T
14 and 26 CAN
Refer to 35C/72
20 and 33 Private CAN
13 and ground Ground monitoring motor and motor relay
AF
Continuity
38 and ground ABS/ESC ECU ground
R
D

ESC 35C
INSPECTION PROCEDURE USING AN ANALYZER / 69
INSPECTION PROCEDURE USING AN ANALYZER WCH35CSHOOT11076
WHEEL SPEED SENSOR

Analyzer connection
T
AF
R
DOIQC35CR11062
D
CONNECTION FOR WHEEL SPEED SENSOR

Description
A) (+) terminal of the analyzer to • Pin terminal no. 1 wheel speed sensor
B) (-) terminal of the analyzer to • Pin terminal no. 2 wheel speed sensor and ground
1. Disconnect the wheel speed sensor connector and connect the special tool (test harness MB 991348)
in between. All terminals should be connected.
2. Connect the analyzer to the test harness to pickup the wheel speed sensor signal at pin no. 1 and
pin no. 2 of the wheel speed sensor to ground.
3. Turn the ignition switch ON.
4. Turn the wheel by hand at approximately 1 revolution per second or drive on brake dynometer
at 5 km/h (3.11 mph).
NOTE
Recommended analyzer setting;
• Y-axis: 2V
• X-axis: 100ms
Repeat the procedure for all the wheel speed sensor

35C ESC
/ 70 INSPECTION PROCEDURE USING AN ANALYZER
Standard Wave Pattern
DOIQC35CR11063
Symbol Description
Output voltage;
V High (range from 0.9 V to 1.5 V)
Low (range from 0.3 V to 0.8 V)
T Time varies according to wheel speed
1. Check the wave generated by the analyzer is the same as the standard wave form when the wheels
is turn at a constant speed.
2. Check that the time (cycle time), t is reduced when the wheel speed increases.
3. If the wave generated is different from the standard waveform, replace the wheel speed sensor.
ALTERNATIVE METHOD- CHECK AT ABS ECU
Analyzer connection
T
AF
R
D
DOIQC35CR11064

ESC 35C
INSPECTION PROCEDURE USING AN ANALYZER / 71
CONNECTION FOR FRONT LH WHEEL SPEED SENSOR

Description
A) (+) terminal of the analyzer to • Pin terminal no. 19 ABS ECU
B) (-) terminal of the analyzer to • Pin terminal no. 8 ABS ECU
1. Disconnect the ABS ECU connector and connect the special tool (test harness MB 991348) in
between. All terminals should be connected.
2. Connect the analyzer to the test harness to pickup the wheel speed sensor signal.
4. Turn the front LH wheel by hand at approximately 1 revolution per second or drive on brake
dynometer at 5 km/h (3.11 mph).
NOTE
• Y-axis: 2V
• X-axis: 100ms
Repeat the procedure for all the wheel speed sensor;
CONNECTION Description
A) (+) terminal of the ana-
• pin terminal no. 16 (A-41) ECU
Front RH Wheel speed lyzer to
sensor B) (+) terminal of the ana-
lyzer to
T • pin terminal no. 4 (A-41) ECU

AF
Rear RH Wheel speed lyzer to
lyzer to
Rear LH Wheel speed lyzer to
R

lyzer to
D
DOIQC35CR11065
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.

35C ESC
/ 72 INSPECTION PROCEDURE USING AN ANALYZER
CAN SIGNAL MEASUREMENT WCH35CSHOOT11077
Analyzer connection
DOIQC35CR11066
CONNECTION DESCRIPTION
Channel 1: Pin terminal no. 6 Diagnosis connector to pin terminal no. 5 Diagnosis CAN-HI
connector
connector
T
Channel 2: Pin terminal no. 14 Diagnosis connector to pin terminal no. 4 Diagnosis
1. Connect the analyzer to the test harness to pickup the CAN signal.
CAN-LO
AF
3. Observe the voltage signal using the analyzer.
NOTE
• Y-axis: 5V
• X-axis: 100ms
R

D
DOIQC35CR11067
1. Check the wave generated by the analyzer is the same as the standard wave form.
2. Check that the voltage value;
SYMBOL STANDARD VALUE DESCRIPTION

V1 - 0.12- - - - V ~ 0.12 V DIFFERENTIAL RECESSIVE VOLTAGE
V2 1.2 V ~ 3.0 V DIFFERENTIAL DOMINANT VOLTAGE
3. If the wave generated and the voltage value is different from the standard, check the wiring
harness.

ESC 35C
ON-VEHICLE SERVICE WCH35CSPROC11018
BOCSH ABS 9 BRAKE FLUID REPAIR CYCLE

WALKTHROUGH
CAUTION
unit from being damaged/overheated.
The vehicle and items should be prepared at the
following condition before carrying out the
brake fluid repair cycle:
• Engine running/Ignition on.
• Ensure that there is no leakage around the
brake fluid distribution.
• Use the specified brake fluid , avoid using a
mixture of the specified brake fluid with
other fluid.
T • Use transparent bleeder hose and bleeder

bottle.
AF
BRAKE CYCLE REPAIR PREPARATION
STEPS
PADT-II PREPARATION
Set up the PADT-II connection to the vehicle
diagnosis connector.
R
Symbol Description
A PADT-II vehicle communica-
tion interface (VCI)
D
B OBD-II cable
C USB cable
DOIQC35CR11022
BRAKE BLEEDING SET UP
NOTE
Follow the PADT-II instruction during hydraulic
bleeding procedure. Remove the bleeder screw
to release the brake fluid every the bleeding
cycle starting from RR, FR, FL and end with RL.

35C ESC
1. Remove the caps of the bleeder screw.
Symbol Description
A Cap
DOIQC35CR11068
2. Connect the transparent bleeder hose of the

transparent bleeder bottle to the bleeder
screw (front axle RH/LH and rear axle RH/LH).
Symbol Description
A Transparent bleeder hose
B Transparent bleeder
T C
bottle
Bleeder screw
AF
DOIQC35CR11069
NOTE
Always pay attention to the reservoir level during
the entire bleeding procedure. Refill when neces-
R
sary.
HYDRAULIC UNIT BLEED WCH35CSPROC11019

D
CAUTION
DOIQC35CR11070
Prepare the brake repair set-up and the PADT-II
VCI connection to the vehicle diagnosis connector
(refer to 35C/7 ).
NOTE:
BEFORE PROCEED, ENSURE THAT
• Ignition On.
• Brake fluid reservoir tank is always at maximum
level.
• Air conditioning is switch “OFF”.
• In case of communication with PADT-II is inter-
rupted, repeat the bleeding process from the
beginning. Wait for 5 minutes before repeating
the process to avoid the hydraulic motor from
overheated.

ESC 35C
Start the process. PADT–II will instruct to open

the bleeder screws as following sequence.
Symbol Description
1 Rear (LH)
2 Front (LH)
3 Front (RH)
4 Rear (RH)
DOIQC35CR11071
T
AF
R
D
DOIQC35CR11073

Symbol Description
Tests’
lect Subsystem’

35C ESC
Symbol Description
ESC9’
T
AF
R
DOIQC35CR11074
D

Symbol Description
cial function’
E Test selection ‘HCU Re-
pair Bleed ESC’

ESC 35C

DOIQC35CR11075
4. Start bleed cycle by opening the bleeder

screw Rear Left. Then select next to proceed.
T
AF
DOIQC35CR11076

RUNNING’
R
NOTE
D
DOIQC35CR11077

DOIQC35CR11078

35C ESC

Front Left. Select next to proceed.
DOIQC35CR11079

RUNNING’
NOTE
T
AF
DOIQC35CR11080

R

D
DOIQC35CR11081

Front Right. Select next to proceed.
DOIQC35CR11082

ESC 35C

RUNNING’
NOTE
DOIQC35CR11083

T
AF
DOIQC35CR11084

Rear Right. Select next to proceed.
R
D
DOIQC35CR11085

RUNNING’
NOTE
DOIQC35CR11083

35C ESC

Press next to proceed to continue.
DOIQC35CR11086
16. The bleeding process is finish. Press Cancel

button to exit after reading the test result.
T
AF
DOIQC35CR11087
Check the following conditions;

• Brake not spongy or brake pedal distance is
acceptable .
R
• No bubble in bleeder hose.

• Pedal free play according to specification.
If result is unsatisfactory, repeat bleeding
process. Always wait for 5 minutes before
D
repeating the bleeding process.
Symbol Description
A Bubble
DOIQC35CR11114

ESC 35C
CALIBRATION / 81
CALIBRATION WCH35CSPROC11020
SPECIAL FUNCTIONS
PRE-CAUTION FOR OPERATING
1. When battery voltage is low, no detection of failure is possible. Be sure to check the battery for
voltage and other conditions before starting the tests.
2. Connection and disconnection of the PADT–II should always be made with the ignition switch in
the OFF position.
3. Fault code can only be erased when ignition switch is in the ON position. After deleting, switch
to “OFF” position and wait 30 sec. before turning ⇒ “ON” the ignition.
T
AF
DOIQC35CR11022
4. Connect PADT-II (VCI) to diagnostic connector (the position of the diagnostic connector varies
between models).
Symbol Description
A PADT-II vehicle communication interface ( VCI )
R
B OBD-II cable
C USB cable
D
NOTE
For details information on the PADT-II, please refer to the PADT-II User Manual.
STEERING ANGLE SENSOR CALIBRATION

WCH35CSPROC11007

Turn steering wheel into
straight, position steer-
Pre-Setting ing angle position - 5
degrees< straight < 5
degrees
DOIQC35CR11088

35C ESC
/ 82 CALIBRATION

REMARKS:
The Steering wheel position for the calibration
of the steering angle sensor must be in a
straight position.The maximum allowed toler-
ance for the calibration amounts ± 5 degrees.
The verification double checks the programmed
code by reading and evaluating of the I/O data
details see below.
The calibration will be initiated after the next
ignition cycle.
NOTE
Calibration data incorrect ~ Failure message,con-
tinue
Calibration data correct ~ continue
Specific Remarks:
The steering angle sensor calibration is a must
!!!!
SPECIAL FUNCTIONS
T
STEERING ANGLE SENSOR CALIBRATION USING SPECIAL FUNCTION IN PADT-II
WCH35CSPROC11021
AF
STEERING ANGLE To ensure that the steering After changing/update new:
SENSOR CALIBRA- angle sensor is calibrated. 1. Engine Control Unit (ECU) or
TION 2. Steering angle sensor or
3. Steering shaft or
4. ABS software
R
D

ESC 35C
CALIBRATION / 83
T
AF
DOIQC35CR11089
R
Select Subsystem
Special Functions
D
Actuator Tests
2. Go to “Select Subsystem” and a list of corrES-
Cond subsystems will appear in the PADT-II
interface.
3. Select one subsystem for Active Tests:
“Chassis System; ABS/ESC Subsystem;
BOSCH—ESC9 ECU Identification” as shown

35C ESC
/ 84 CALIBRATION
T
AF
DOIQC35CR11090
R

5. Then, click on “Steering Angle Sensor Calib-
ration”.
D

DOIQC35CR11091

ESC 35C
CALIBRATION / 85
7. Please ensure the steering wheel is ‘0’ degree

(±5 degrees) before starting the calibration
process. Then go to “Next” button.
DOIQC35CR11092
8. Make sure the pre-conditions are met:
No Parameter name Pre-condition

value
1 Battery voltage >10 V
T
AF
DOIQC35CR11093
9. Steering angle sensor calibration test com-

pleted successfully. Press ”Exit” button to re-
turn to Main Menu.
R
D
DOIQC35CR11094

35C ESC
/ 86 CALIBRATION
ACCELERATION SENSOR (Ax) CALIBRATION WCH35CSPROC11008
T
AF
R
DOIQC35CR11095
ACCELERATION SENSOR OFFSET VALUE TRIMMING

• Turn steering wheel into straight position
D
Pre-Setting
• Car should stand in straight position on the equipment
CONDITIONS BEFORE THE SENSOR COULD BE TRIMMED:
• Maximum allowed inclination angle of the test rig ± 0.57 degrees (1%)
• Steering wheel in a straight position
• Correct tire pressure
• Normal loading condition
• Low capacity of the vehicle tank
• Car is standing on the wheels
• Only the driver should be sit in the car
NOTE
Trimming incorrect ~ Failure message,continue
Trimming correct ~ continue

ESC 35C
CALIBRATION / 87
SPECIAL FUNCTIONS WCH35CSPROC11022
ACCELERATION SENSOR CALIBRATION USING SPECIAL FUNCTION IN PADT-II

ACCELERATION To ensure that the acceleration After changing/update new:
SENSOR CALIBRA- sensor is calibrated. 1. Engine Control Unit (ECU) or
TION 2. Acceleration sensor or
3. ABS software
T
AF
R
D
DOIQC35CR11089
Select Subsystem
Special Functions
Actuator Tests
2. Go to “Select Subsystem” and a list of corres-
pond subsystems will appear in the PADT-II
interface.
3. Select one subsystem for Active Tests:
“Chassis System; ABS/ESP Subsystem;
BOSCH—ESP9 ECU Identification” as shown

35C ESC
/ 88 CALIBRATION
T
AF
DOIQC35CR11096
R

5. Then, click on “Acceleration Sensor Calibra-
tion”.
D

DOIQC35CR11097

ESC 35C
CALIBRATION / 89
7. Please ensure the steering wheel is ‘0’ degree

(±5 degrees) and slope inclination is ±0.5
degrees before starting the calibration pro-
cess. Then go to “Next” button.
DOIQC35CR11098
8. Make sure the pre-conditions are met:
No Parameter name Pre-condition

value
1 Battery voltage >10 V
T
AF
DOIQC35CR11099
9. Acceleration sensor calibration test com-

pleted successfully. Press ”Exit” button to re-
turn to Main Menu.
R
D
DOIQC35CR11100

35C ESC
/ 90 ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU)
ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU) WCH35CSASSY11005
T
AF
R
DOIQC35CR11101
D
• Brake fluid draining.
• Brake line bleeding.
• Brake pedal adjustment.
Removal steps
1. ABS-ECU connector 7. Brake pipe connection MC2
2. 8. Bracket assy
Brake pipe connection RL
3. 9. Electronic Hydraulic Control Unit (EHCU)
Brake pipe connection FR
4. 10. Nut 10m
Brake pipe connection FL
5. 11. Washer
Brake pipe connection RR
6. 12. Damper rubber
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

ESC 35C
ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU) / 91
REMOVAL SERVICE POINT WCH35CSPROC11009

CAUTION
(1) The hydraulic unit assembly is heavy and be
carefully during removal.
(2) The hydraulic unit assembly cannot be disas-
sembled.
dropped or otherwise subjected to impact
shocks.
turned upside down or laid on its side.
BRAKE PIPE CONNECTION
Connect the pipes to the hydraulic unit assembly
T Symbol
1
2
Description
To w/cylinder (FR)
To w/cylinder (RL)
AF
3 To w/cylinder (RR)
4 From the master cylinder (Secondary)
DOIQC35CR11115
5 From the master cylinder (Primary)
A Hydraulic unit ( EHCU)
R

D
CAUTION
(1) The hydraulic unit assembly is heavy and be carefully during removal.
(2) The hydraulic unit assembly cannot be disassembled.
(3) The hydraulic unit assembly must not be dropped or otherwise subjected to impact shocks.
(4) The hydraulic unit assembly must not be turned upside down or laid on its side.
ABS CONNECTOR
Connector ABS to the hydraulic unit assembly as
Symbol Description
A Push Lock connector
B Pull – up lever
DOIQC35CR11102

35C ESC
DOIQC35CR11103
WHEEL SPEED SENSOR WCH35CSASSY11006
T
AF
R
D
DOIQC35CR11104

ESC 35C
• Wheel speed sensor output voltage check.
Front speed sensor (A) removal steps
1. Front speed sensor
2. Front rotor (Refer to Module 1.7 GROUP 026 – Drive shaft).
Rear speed sensor (B) removal steps
3. Rear speed sensor
4. Rear rotor (Refer to Module 1.7 GROUP 027 – Rear axle hub).
NOTE
(1) The front rotor is integrated with the drive shaft and disassembled.
(2) The rear rotor is integrated with the rear hub and cannot be disassembled.
T1: 0.6-0.8 kgf.m
T
AF
R
D

35C ESC
FRONT SPEED SENSOR / REAR SPEED SENSOR

REMOVAL
CAUTION
Be careful when handling the pole piece (PP) at
the tip of the speed sensor and the rotor teeth.
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)
T
AF
DOIQC35CR11105
FRONT SPEED SENSOR / REAR SPEED

R
SENSOR INSTALLATION
FRONT SPEED SENSOR INSTALLATION
CAUTION
D

Standard value (C):
1.0 ± 0.1 mm (0.039 ± 0.004 in)
Symbol Description
A Front sensor
B Front rotor
DOIQC35CR11106 C 1.0 ± 0.1 mm (0.039 ± 0.004 in)

ESC 35C
Symbol Description
E ABS front sensor
REAR SPEED SENSOR INSTALLATION
CAUTION
Standard value (C):
1.0 ± 0.1 mm (0.039 ± 0.004 in)
T Symbol
A
Description
Rear sensor
AF
B Rear rotor
C 1.0 ± 0.1 mm (0.039 ± 0.004 in)
F ABS rear sensor
DOIQC35CR11107
R
D

35C ESC
/ 96 ACCELERATION SENSOR
ACCELERATION SENSOR WCH35CSASSY11007
T
AF
R
DOIQC35CR11108
D
CAUTION
(1) Do not use impact wrench.
(2) Do not drop or shock the acceleration sensor.
(3) When the acceleration sensor is replaced or installed, always carry out calibration to make ESC-
ECU learn the neutral point (Refer to 35C/86 ).
• Turn the ignition key to the “LOCK” position
• Floor Console Removal (Refer to group 52A: Floor console)
Removal steps
• Post-installation inspection
1. Floor console assembly
2. Connection for the ESC control unit and the harness connector
3. ESC control unit
T1 5.9~6.2 kgm (59~62 Nm, 42.67~44.84 ft.lbs)

ESC 35C
SWITCH CENTER ASSEMBLY / 97
SWITCH CENTER ASSEMBLY WCH35CSASSY11008
T
AF
R
DOIQC35CR11109
D
Removal steps
1. Center air outlet
2. Switch assy center

35C ESC
/ 98 SWITCH CENTER ASSEMBLY
CENTER AIR OUTLET AND SWITCH CENTER

ASSEMBLY REMOVAL
1. Remove the gear knob (M/T).
2. Remove the shift lever cover assy (Refer to
GROUP 52A – Floor console).
3. Remove the center panel assy (Refer to
GROUP 52A – Floor console ).
4. Remove the center air outlet assy mounting
screw (2 pieces).
DOIQC35CR11110
T
AF
5. Use the special tool to pry out the center air
outlet assy.
R
D
DOIQC35CR11116
6. Disconnect the switch center assembly con-

nectors (2 pieces of connector).
Symbol Description
A Switch Center A
Connector No. D-18 (7 pins)
B Switch Center B
Connector No. D-19 (16 pins)
DOIQC35CR11117

ESC 35C
7. Remove the switch center assembly mounting

screw (2 pieces) and remove the switch center
assembly from the center air outlet.
Symbol Description
A Switch center assembly
B Center air outlet
C Mounting screw
DOIQC35CR11111
WHEEL SPEED SENSOR CHECK

CAUTION
T
ent.
AF
Symbol Description
A Wheel speed sensor
DOIQC35CR11112
B Wheel speed sensor harness con-
nector (A-40, A-39 ,E-21, E-20)
C ABS ECU
R
D ABS ECU harness connector (A-41)

1. Remove the wheel speed sensor.
2. Disconnect the ABS ECU connector.
3. Check at the harness side;
D
Connect- Pin terminal Description

or
A-41 8 and 19 Wheel speed
sensor Front LH
Condition: Ignition switch ON
1. Continuity check, OK: continuity
2. Short circuit (to ground/battery), OK: no
short circuit
DOIQC35CR11113 NO GOOD: Check the wiring harness. If
problem still exist, replace wheel speed
sensor. If all test fail, replace ABS ECU.
4. Repeat test for other wheel speed sensor

Wheel speed sensor
4 and 16
Front RH
17 and 29
RH

35C ESC

31 and 18
LH

WCH35CSPROC11014

Symbol Description
A Operating rod
B Operating rod lock nut
C Stop lamp switch
D Brake pedal height
DOIQC35CR11118 Standard value:
163.4- 166.4 mm (6.43- 6.55 in) (D).
T
nector.
AF
obtained.
Symbol Description
A Pedal down
R
B Pedal up
C Lock nut
DOIQC35CR11119
D
operating rod.
firmly.)
switch.

ESC 35C
2. Start the engine, depress the brake pedal

ance between the brake pedal and the floor
board.
Standard :

check for air trapped in the brake line,
DOIQC35CR11120 and replace defective parts as required.
pushed in the and when it is released. The stop
lamp switch is in good condition if there is no
T
continuity when the plunger is pushed in to a
depth of within 4 mm (0.16 in) from the outer
case edge surface, and if there is continuity when
AF
it is released
Symbol Description
DOIQC35CR11121
A 4 mm (0.16 in)
B No continuity
C Continuity
R

D

then stop it
Symbol Description
DOIQC35CR11122
A Good
B No good

35C ESC
2. With the engine stopped, step on the brake

pedal several times.
engine
Symbol Description
DOIQC35CR11123
If the above tests are okay, the booster per-
of the above three test is not okay at last ,
T the check valve , vacuum hose or booster will

be defective.
AF
The brake fluid sensor is in good condition if
there is no continuity when the float surface is
above “MIN” and if there is continuity when the
float surface is below “MIN”.
R
Symbol Description
A “MIN”
D
DOIQC35CR11124
BLEEDING
CAUTION
mixture of the specified brake fluid and other
fluid.
• Safety item
• Goggle
• Pour water, to neutral area
Specified brake fluid
: DOT3 or DOT4
DOIQC35CR11125
MASTER CYLINDER BLEEDING
The master cylinder used has no check valve, so
if bleeding is carried out by the following proced-
ure, bleeding of air from the brake pipeline will
become easier. (When brake fluid is not con-
tained in the master cylinder.)

ESC 35C
1. Fill the reservoir tank with brake fluid.

2. Keep the brake pedal depressed.
3. Have another person cover the master cylin-
der outlet with a finger.
4. With the outlet still closed, release the brake
pedal.
5. Repeat steps 2–4. three or four times to fill
the inside of the master cylinder with brake
fluid.
BRAKE PIPE LINE BLEEDING
Bleed the air in the sequence shown in the fig-
ure.
CAUTION
For vehicles with ABS, be sure to install a filter
to the master cylinder reservoir tank when sup-
plying brake fluid.
DOIQC35CR11126
T
AF
R
D

35C ESC
NOTE
T
AF
R
D

PARKING BRAKES 36
Content /1
36 PARKING BRAKES
INFORMATION ....................................................................... 36/2
CONSTRUCTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36/2
SPECIFICATIONS ....................................................................... 36/2

LUBRICANTS ......................................................................... 36/3
PARKING BRAKES ..................................................................... 36/3

ON VEHICLE SERVICE ............................................................... 36/3
PARKING BRAKE LEVER STROKE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36/3
PARKING BRAKE ADJUSTMENT .................................................. 36/4
PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36/5
PARKING BRAKE LEVER ............................................................. 36/6

T
AF
R
D

36 PARKING BRAKES
INFORMATION
The parking brake is of a mechanical control type acting on the rear-wheel. A lever is used to apply
the parking brake. The operation method utilizes a parking brake lever which is in an offset position
at the passenger's side.
T
AF
R
D
DOIQC036R11001
Item Description
1 Parking brake lever
2 Parking brake cable
Type Mechanical brake acting on rear wheels
Brake lever type Lever type
Cable arrangement V-type

PARKING BRAKES 36
PARKING BRAKES /3
Items Model Standard
Parking brake lever stroke (Oper-
ation: Approx. 20 kg (200 N, 44.1 1.6L (Disc) 5 - 6 notches
lbs)
LUBRICANTS
Items Quantity Specified lubrications
Backing plate
Adjuster As necessary Brake grease : SAE J310, NLGI No. 1.
Parking lever pin end
PARKING BRAKES WCH036SPROC11001
ON VEHICLE SERVICE
PARKING BRAKE LEVER STROKE CHECK
1. Pull the parking brake lever with a force of approximately. 20 kg and count the number of notches.
T
Standard value: 5 – 6 notches
2. Lever must operate smoothly without rattle after assembly,and pawl must fit securely on tooth
of ratchet.
AF
Rotary torque max. 10kgf.cm
R
D

36 PARKING BRAKES
/4 PARKING BRAKES
PARKING BRAKE ADJUSTMENT
T
AF
R
DOIQC036R11002
1. Loosen the nut adjuster at the floor console

until the end of stud thread.
D
Symbol Description
A Stud thread
B Nut adjuster
2. After loosening the nut adjuster, ensure the
parking brake lever at the released position.
Symbol Description
C Parking brake lever
3. Remove tyre (Refer to GROUP-031-Wheel and
Tyre ) and drum brake (Refer to GROUP-35B).
4. Remove the drum brake from brake system
.
DOINC036R08005

PARKING BRAKES 36
PARKING BRAKES /5
5. Turn the drum brake auto adjuster (F) in or-

der to expand the brake shoe.
6. Fix the drum brake (G) into the drum
shoe,turn the drum and feel the dragging.
7. Follow the procedures No.4 until No.6 for
another rear drum brake.
8. After completing the procedures at rear
wheel,continue adjusting the nut at parking
brake.
9. Adjust the nut adjuster parking brake until
6 to 8 notches.
10. After making adjustment , check to ensure
that there is no looseness between the adjust-
ing nut and parking brake lever.Also check
that the cable adjusting is securely held to
the nut holder.
Symbol Description
E Screw driver
1
F Auto adjuster
T 2
3
G
H
Fix drum brake
Turn the drum and feel the
dragging
AF
DOINC036R08006
PARKING BRAKE SWITCH

1. Remove the floor console. (Refer to GROUP
R
52A-Floor Console)
2. Check for continuity between the parking
brake switch terminal and the switch
mounting bolt.
D
When parking brake lever Continuity

is pulled
When parking brake lever No Continuity
is released
DOIQC036R11003

36 PARKING BRAKES
/6 PARKING BRAKE LEVER
PARKING BRAKE LEVER WCH036SASSY11001
T
AF
R
DOIQC036R11004
D
Grease : Repair kit grease

• Floor console removal ( Refer to GROUP– 52A).
• Parking brake lever adjustment.
• Floor console installation.
Removal steps
1. Cable adjuster
2. Nut holder
3. Parking brake switch
4. Parking brake lever assembly
5. Cable equalizer
6. Cable parking brake
7. Panel assy backbone
T1:1.0 - 1.3 kgm (10 - 13 Nm, 7.23 - 9.4 ft.lbs)

STEERING 37A
Content /1
37A STEERING
INFORMATION ....................................................................... 37A/4
CONSTRUCTION DIAGRAM ....................................................... 37A/5

SERVICE SPECIFICATIONS .......................................................... 37A/6
LUBRICANTS ......................................................................... 37A/6
SEALANT ............................................................................. 37A/6
SPECIAL TOOLS ........................................................................ 37A/7

TOOLS ................................................................................ 37A/7

SYMPTOM ............................................................................ 37A/9
Note .................................................................................. 37A/11
ON VEHICLE SERVICE ................................................................. 37A/12

STEERING WHEEL FREE PLAY CHECK ............................................ 37A/12
T
STEERING ANGLE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/12
TIE ROD END BALL JOINT STARTING TORQUE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/13
STATIONARY STEERING EFFORT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/13
FEAD BELT TENSION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/14
AF
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/14
FLUID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/15

BLEEDING ............................................................................. 37A/15
OIL PUMP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/16
POWER STEERING OIL PRESSURE SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/18
R
STEERING WHEEL AND SHAFT ..................................................... 37A/19

D

STEERING ANGLE SENSOR ............................................................ 37A/26
STEERING ANGLE SENSOR ............................................................ 37A/28
STEERING LINKAGE ................................................................... 37A/29

STEERING LINKAGE TOTAL PINION TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/31
CHECK THE BALL JOINT FOR SWING ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/31
OUTER BALL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/32
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/32
LUBRICATION AND SEALING POINT ............................................. 37A/36
POWER STEERING OIL PUMP ....................................................... 37A/38

REMOVAL AND INSTALLATION (ENGINE CFE) ................................. 37A/38
POWER STEERING OIL PUMP ..................................................... 37A/39
REMOVAL AND INSTALLATION (ENGINE IAFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37A/39

37A STEERING
/2 Content
POWER STEERING HOSES ........................................................... 37A/40

T
AF
R
D

STEERING 37A
Content /3
NOTE
T
AF
R
D

37A STEERING
INFORMATION
The steering wheel is a 3–spoke type with SRS. The steering column is equipped with bolt shock ab-
sorbing and a tilt steering mechanism. The power steering is an integral rack and pinion type that
combines the gear and linkage into one light-weight and compact assembly. The steering system uses
a vane oil pump with a fluid flow control system, so that steering effort varies with engine speed.
Item Specification
Steering gear and link- Type Fixed- type
age Gear type Rack and pinion
Type Vane type
Oil pump Displacement (cm3/rev) 8.1 cm³/rev (0.49 cu.in/rev)
Relief set pressure 65 kgf/cm
2
T
AF
R
D

STEERING 37A
T
AF
R
DOINC37AR08025
Symbol Description
1 Steering wheel
D
2 Steering shaft
3 Shaft assembly
4 Hose assembly, pressure
5 Tube assembly, return (G)
6 Hose suction
7 Reservior,oil assembly
8 Hose,return (R)
9 Power steering pump
10 Tube assembly,cooler
11 Steering linkage

37A STEERING
/6 SPECIFICATIONS
SPECIFICATIONS WCH37ASPECS11002
Item Standard Value Allowance Limit
10 mm (0.39 in) or less — —
Steering Wheel Free Play
— — 30 mm (1.18 in)
+ 0.5°
32.7° —
- 0.5°
Steering Angle
+ 0.5°
38.9° —
- 0.5°
Tie rod end ball joint start-
0.02 - 0.048 kgf.m — —
ing torque
Stationary steering effort
3.5 kgf.m or less — —
(Fluctuation allowance)
8.8 MPa — —
Oil pump pressure 0.2–0.5 MPa — —
8.8 MPa — —
Oil pressure switch operating
pressure
Total pinion preload
1.5–2.0 MPa
0.7–2.0 MPa
T —
—
—
—
AF
(Change in torque: ) 0.06 - 0.14 kgf.m — —
0.04 kgf.m
Tie rod joint swing resistance
1.5 - 4.9 kgf.m — —
(Tie rod joint swing torque)
LUBRICANTS
R
Items Specified lubricant Quantity

Power steering fluid Automatic transmission fluid - ATF As required
DEXRON II
D
Bellows Silicone grease As required

Oil seal, pinion and valve
assembly, ball bearing,
needle roller bearing.
Flow control valve, friction Automatic transmission fluid As required
surface of rotor, vanes,
cam ring, pump cover, O-
ring
SEALANT
Power steering rack sup-
port cover screw
3M ATD Part No. 8661 or equivalent Semi-drying sealant
Dust cover lip for tie rod
end ball joint

STEERING 37A
SPECIAL TOOLS /7
TOOLS
• Measurement of
the bolt joint
starting torque
MB990685 Torque wrench
• Measurement of
the pinion shaft
preload
DOIIC37AR9002
Measurement of the
MB990326 Preload socket ball joint starting
torque
DOIIC37AR9003
T
MB991006 Preload socket.
Measurement of the
AF
pinion shaft preload
DOIIC37AR9018
MB991113 or Steering linkage • Removal of the

MB990635 puller. lower arm ball
joint and
R
knuckle
• Removal of the
knuckle and tie
rod end ball
D
DOIIC026R9003
joint
MB990803 Steering wheel Disconnection of
puller. the steering wheel.
DOIIC52BR9003

37A STEERING
/8 SPECIAL TOOLS

MB990994 Power steering
oil pressure
gauge adapter
(hose)
DOIIC37AR9015
MB990993 Power steering

oil pressure
gauge adapter
To measure the oil
(pump side)
pump pressure
DOIIC37AR9004
MB990662 Oil pressure

gauge assembly
DOIIC37AR9016
T
AF
R
D

STEERING 37A
TROUBLESHOOTING /9
SYMPTOM
Symptom Probable cause Checking procedure Remedy
Damage Fead-belt for Visually check the Fead- Replace the Fead-
belt for stretching, deteri-
stretching, deterioration, belt
peeling and wear oration, peeling and wear
(1) Visually check the fluid Replenish the flu-
Insufficient fluid
level in the reservoir tank id
Fluid leakage Leakage from hose con- Retighten or re-
nections, or from oil place
(2)
pump or gear box seals
Twisted or damaged hoses make visual inspection Correct the rout-
ing or replace the
hoses
Improper installation of Loosen and then retight- Correct
the steering gear to the en the mounting bolts
gear housing bracket
Steering wheel operation

is heavy (at low speed in all
range) or excessive differ-
No increase in oil pump
pressure
T Check oil pressure (with Replace the oil

gauge valve opened) with pump (If the
the steering wheel at the trouble persists
AF
neutral position and check after replacement
ence in torque during
the maximum generated of the oil pump,
steering wheel operation
oil pressure (with gauge replace the steer-
(3) ing gear box)
valve closed)
Malfunction of pinion and Check oil pressure (with Replace the steer-
valve (including damaged gauge valve opened) with ing gear box
R
seals) the steering wheel at the

Damaged rack piston seal neutral position and check
the maximum generated
oil pressure (with gauge
D
(4)
valve closed)
Improper front wheel Correct the wheel alignment
alignment
Excessively tighten rack Measure the total pinion Adjust the rack
support preload support
Excessive friction of steer- Check the turning torque Replace the tie
ing linkage of the ball joint rod end

37A STEERING

Improper front wheel Correct the wheel alignment
alignment
Improper rotation of the Turn the steering wheel Replace
bearing in the steering and confirm that there is
shaft joint no binding
Improper rotation of tie Check the ball joint for Apply grease or
rod end and/or ball joint play and confirm that replace the tie rod
there is sufficient grease end
The steering wheel does Excessively tightened rack Measure the total pinion Adjust rack sup-
not return properly support preload port or replace
gear box
Damaged gear sliding Measure the total pinion If the specified
portion or turning portion preload and confirm that torque is not
Bent rack there is no excessive available by ad-
change between loss and justment of the
lock rack support, re-
place the gear
box
joint or worn ball joint
T
Loose steering linkage ball Check tightening torque
Check the turning torque
of the ball joint
Retighten
Replace the tie
rod or tie rod end
AF
Improper mounting of the Check tightening torque Retighten
Lack of driving stability
Cross member gear
Loose rack support Check tightening torque Adjust the rack
Measure the total pinion support
preload
R
Tyres (assuming that the Rotate tyres

tyres inflation pressure,
Drifts to one side tyres wear, front align-
ment and front wheels are
D
all normal )
Air in the system due to Visually check the fluid Replenish fluid
insufficient fluid level in the reservoir tank Bleed air
Air drawn into piping Check the piping connec- Retighten or re-
Abnormal noise (Creaking
tions for fluid leakage place the hose
sound, squeaking
Bleed air
Crushed suction hose Check the suction for de- Correct or replace
formation

STEERING 37A

Slipping Fead-belt Check the Fead-belt ten- Adjust the Fead-
sion belt tension
Check the Fead-belt for Replace the Fead-
damage belt
Damage Fead-belt Visually check the Fead- Replace the Fead-
belt for stretching, deteri- belt
oration (cracking),peeling
or wear
Heat-damage oil pump Turn the oil pump pulley Replace the oil
manually and confirm pump
Abnormal noise (Creaking that it turns freely
sound, squeaking sound) Loose gear box bracket Check the tightening Retighten
torque
Loosen steering linkage Check the tightening Retighten
and ball joint installations torque
Loose steering linkage and Measure the ball joint Replace the tie
ball joint turning torque rod end
T
Interference of the piping Check the piping-to-body Correct the piping
with the body clearance
Free play exceeds normal Measure the total pinion Adjust the rack
AF
spec preload support
NOTE:
(1) Since fluid leakage is suspected, make through check. Especially, confirm that there is no fluid leakage into the gear bellows.
(2) The connection between gear box and piping is sealed with O-ring . Before retightening the connection, therefore, check thoroughly
that O-ring is free from damage.
(3) Make measurement at an oil temperature of 50-60 °C (122-140 °F). Be sure to set the engine speed to 1000 r/min ± 100 r/min.
(4) Make measurement at an oil temperature of 50-60 °C (122-140 °F). Be sure to set the engine speed to 1000 r/min ± 100 r/min.
Note
R
1. When the steering wheel is turned while the vehicle is standing still, the oil pump will make a soft
humming sound. This sound is caused by the pulsing of the fluid inside the pump, and does not
indicate a malfunction.
D
2. If The steering wheel is turned while the brake pedal is being depressed, some sound may be
heard from the brakes. This sound is caused by the sticking of the brake pads as the tyres turn,
and does not indicate a malfunction.
3. When the steering wheel is turned while vehicle is standing still, short squeaking sounds may be
heard. These sounds are caused by the fluid flowing through the pressure control valve, and do
not indicate a malfunction.
4. Sound will be hear (“piss” sound) once steering is turn at full lock at both sides.This sound come
from discharge pressure of PAS pump(normal for pump).

37A STEERING
/ 12 ON VEHICLE SERVICE
ON VEHICLE SERVICE WCH37ASPROC11004
STEERING WHEEL FREE PLAY CHECK

1. When engine running ( hydraulic operation
), set front wheels straight a head.
DOIQC37AR11001
2. Measure the play on steering wheel circum-

ference before wheels start to move when
slightly moving steering wheel in both direc-
tions
Limit :
30 mm (1.18 in)
T 3. When play exceeds the limit, check for play

on steering shaft connection and steering
linkage. Correct or replace.
AF
4. If the free still exceeds the limit value, set
steering wheel straight ahead with engine
DOIQC37AR11002 stopped. Load 0.5 kgf towards steering wheel
circumference and check play.
Standard value (steering wheel play with
engine stopped):
R
10 mm (0.39 in) or less
If the play exceeds the standard value, re-

move steering gear box and check total pin-
D
ion torque.
STEERING ANGLE CHECK
1. Locate front wheels on turning radius gauge
and measure steering angle.
Standard value :
Standard Value Allowance

+ 0.5 °
Inner Wheel 33.6 °
- 0.5 °
+ 0.5 °
Outer Wheel 40.5°
- 0.5 °
2. When the angle is not within the standard
DOIHC37AR05014 value, the toe is probably incorrect. Adjust
toe ( Please refer to “On-Vehicle Service”
GROUP 33A) and recheck steering angle.

STEERING 37A
ON VEHICLE SERVICE / 13
TIE ROD END BALL JOINT STARTING TORQUE

CHECK
1. Remove split pin .
Symbol Description
A Split pin
B Tie rod end
DOIQC37AR11003
2. Slightly loosen the nut only.
Symbol Description
C Tie rod nut
D Special tool – MB991113
CAUTION
T (1) By using the special tool, loosen the tie

rod end mounting nut. Only loosen the
nut but do not remove it from the ball
AF
joint.
(2) Support the special tool with a cord, etc
R
D
DOIQC37AR11004
STATIONARY STEERING EFFORT CHECK

1. With the vehicle stopped on a flat, paved
surface, turn the steering wheel to the
straight ahead position.
2. Start the engine and set it to 1000 r/min ±
100 r/min.
CAUTION
After checking the engine r/min must return
to the standard idling r/min.
3. Attach a spring balance to the outer circum-
ference of the steering wheel and measure
DOIQC37AR11002 the steering force required to turn the

37A STEERING
/ 14 ON VEHICLE SERVICE
steering wheel from the straight ahead pos-

ition to the left and right (within a range of
1.5 turns).
Also check to be sure that there is no signific-
ant fluctuation of the required steering
force.
Standard value:
Steering effort : 5kgf.m or less
Fluctuation allowance : 2.0kgf.m or less
FEAD BELT TENSION CHECK

Refer to GROUP 11A— On-vehicle service .
FLUID LEVEL CHECK
1. Park the vehicle on a flat, level surface, start
the engine, and then turn the steering wheel
several times to raise the temperature of the
fluid to approximately 50-60 °C (122-140 °F).
2. With the engine running, turn the wheel all
the way to the left and right several times.
T 3. Check the fluid in the oil reservoir for form-

ing or milkiness.
Check the difference of the fluid level when
AF
the engine is stopped, and while it is run-
ning. If the change of the fluid level is 5 mm
DOIIC37AR9025
(0.2 in) or more, air bleeding should be done.
Symbol Description
A Fluid level change : Within 5 mm
R
(0.2 in)
B While engine running
C While engine stopped
D

STEERING 37A
FLUID REPLACEMENT
1. Raise the front wheels on jack, and then
support them with rigid racks.
2. Loosen 1 piece bolt of tube assy return G.
3. Remove clip at tube assy return G.
CAUTION
Be careful not to position the high-tension
cable near the delivery pipe.
Symbol Description
A Tube assy return G
B Clip
4. While operating the starting motor intermit-
tently, turn the steering wheel all the way
to the left and right several times to drain
all of the fluid.
5. Fill the oil reservoir with the specified fluid
up to the lower position of the filter, and
then bleed the air.
T Specified fluid :
Automatic transmission fluid= DEXRON II
AF
DOIQC37AR11006
BLEEDING
1. Jack up the front wheels and support them
by using a rigid rack.
R
2. Manually turn the oil pump pulley a few

times .
3. Turn the steering wheel all the way to the
left and to the right five or six times.
D
4. Disconnect the high-tension cable.

CAUTION
Be careful not to position the high-tension
cable near the delivery pipe.
5. While operating the starting motor intermit-
tently, turn the steering wheel all the way
to the left and right five or six times (for 18
to 20 seconds).
CAUTION
(1) During air bleeding, replenish the fluid
supply so that the level never falls below
the lower position of the filter.
(2) If air bleeding is done while engine is
running, the air will be broken up and
absorbed into the fluid; be sure to do
the bleeding only while cranking.
6. Connect the high-tension cable.

37A STEERING
7. Turn the steering wheel to the left and right

until there are no air bubbles in the oil
reservoir.
8. Confirm that the fluid is not milky, and that
the level is up to the specified position on
the level gauge.
9. Confirm that there is very little change in the
fluid level when the steering wheel is turned
left and right.
10. Check whether or not the change in the fluid
level is within 5 mm (0.2 in) when the engine
is stopped and when it is running .
Symbol Description
A Fluid level change : Within 5 mm
(0.2 in)
B While engine running
C While engine stopped
11. If the change of the fluid level is 5 mm (0.2
DOIIC37AR9027
T in) or more , the air has not been completed

bled from the system, and thus must be bled
completely.
AF
OIL PUMP PRESSURE TEST
1. Disconnect the pressure hose from the oil
pump, and then connect the special tools.
2. Bleed the air, and then turn the steering
wheel several times while the vehicle is not
moving so that the temperature of the fluid
R
rises to approximately 50-60 °C (122-140 °F).

3. Start the engine and idle it at 1000 r/min ±
100 r/min.
4. Fully close the shut-off valve of the pressure
D
gauge and measure the oil pump relief

pressure to confirm that it is within the
standard value range.
Standard value:
8.8 MPa
CAUTION
Pressure gauge shut off must not remain
closed for more than 10 seconds.
Symbol Description
1 Temperature gauge
2 Reservoir
3 Adapter (MB990994)
4 Pressure hose
DOIIC37AR9028
6 Oil pump relief pressure
7 Pressure gauge (MB990662)

STEERING 37A
Symbol Description
8 Shut-off valve
9 Oil pump
5. If it is not within the standard value, replace
the oil pump.
6. Check whether or not the hydraulic pressure
is the standard value when no-load condi-
tions are created by fully opening the shut-
off valve of the pressure gauge.
Standard value :
0.2–0.5 MPa.
7. If it is not within the standard value, the

probable cause is a malfunction of the oil
line or steering gear box, so check these parts
and repair as necessary.
8. Fully open the shut-off valve of the way to
the left or right; then check whether or not
the retention hydraulic pressure gauge.
T
9. Turn the steering wheel all the way to the
left or right; then check whether or not the
retention hydraulic pressure is the standard
AF
value.
Standard value:
8.8 MPa
10. When not within the standard value, replace

the power steering gear box.
Remeasure fluid pressure.
R
11. Remove the special tools, and then tighten

the pressure hose to the specified torque.
Tightening torque :
1.7 kgf.m
D
12. Bleed the system.

37A STEERING
POWER STEERING OIL PRESSURE SWITCH CHECK

Symbol Description
1 Temperature gauge
2 Reservoir
3 Oil pump
6 Shut-off valve
1. Disconnect the pressure hose from the oil
pump, and then connect the special tools.
2. Bleed the air, and then turn the steering
wheel several times while the vehicle is not
moving so that the temperature of the fluid
rises to approximately50-60 °C (122-140 °F)
3. The engine should be idling.
4. Disconnect the connection of the connector
for the oil pressure switch and place an
ohmmeter in position.
T 5. Gradually close the shut-off valve of the

pressure gauge and increase the hydraulic
pressure, then check whether or not the hy-
AF
draulic pressure, then check whether or not
the hydraulic pressure that activates the
switch is the standard value.
DOIIC37AR9029
Standard value:
1.5–2.0 MPa
6. Gradually open the shut-off valve and reduce

R
the hydraulic pressure; then check whether

or not the hydraulic pressure that deactivates
the switch is the standard value.
D
Standard value :
0.7–2.0 MPa
7. Remove the special tools, and then tighten

the pressure hose to the specified torque
Tightening torque:
1.7 kgf.m
8. Bleed the system.

STEERING 37A
STEERING WHEEL AND SHAFT / 19
STEERING WHEEL AND SHAFT WCH37ASASSY11007
T
AF
R
D
DOIQC37AR11005

37A STEERING
/ 20 STEERING WHEEL AND SHAFT
CAUTION
For vehicles with SRS,
Before removing steering linkage and ignition key ,refer to GROUP 52B and GROUP 054 accordingly.
Failure to do so may damage the SRS clock spring and render the SRS system inoperative. This risks
serious driver injury to the driver.
• Instrument under cover Removal (Refer to Group 52B -Instrument panel)
• Instrument under cover Installation (Refer to Group 52B- Instrument panel)
• Checking steering wheel position with wheels straight ahead
Removal Steps
1. Horn pad screw (torx type)
2. Horn pad/ Air bag module
3. Steering wheel
4. Upper column cover
5. Lower column cover
6. Clock spring *
T
7. Column switch
8. Steering shaft
T1: 1.8 - 2.6 kgm (18 - 26 Nm, 13.02 - 18.81 ft.lbs)
AF
T2: 0.9 - 1.4 kgm (9 - 14 Nm, 6.51 - 10.13 ft.lbs)
T3: 1.5 - 2.0 kgm (15 - 20 Nm, 10.85 - 14.47 ft.lbs)
T4: 0.7 - 1.1 kgm (7 - 11 Nm, 5.06 - 7.96 ft.lbs)
T5: 3.4 - 4.5 kgm (34 - 45 Nm, 24.59 - 32.55 ft.lbs)
NOTE
* Clock spring with Air bag Module
R
D

STEERING 37A
HORN PAD /SRS PAD REMOVAL

1. Untighten the steering wheel horn pad screw
(torx type) as shown in the illustration.
DOINC37AR09001
2. Move slightly the horn pad from the steering

wheel.
3. Disconnect horn pad connector.
Symbol Description
A Horn pad connector
T
AF
DOINC37AR09016
STEERING WHEEL REMOVAL

1. Marking (A) the steering wheel as shown in
R
the illustration.
D
DOIJC37AL06009
2. Loosen nut steering shaft shown in illustra-

tion.
DOINC37AR09017

37A STEERING
3. Use special tool MB990803 to remove steer-

ing wheel from shaft.
4. Disconnect 4 connectors from column switch
harness.
• Connector column switch (wiper side)
• Connector column switch (signal side)
• Connector column switch (int)
• Connector column switch (horn and SRS
side).
DOINC37AR09018
STEERING SHAFT REMOVAL

1. Marking (A) the steering shaft as shown in
the illustration.
Symbol Description
A Marking
T B Steering shaft
AF
DOINC37AR08026
2. Remove 1 piece bolt at steering shaft end

portion (connection between steering link-
age and steering shaft).
R
Symbol Description
C Steering shaft end portion
bolt
D
DOIQC37AR11008
3. Remove 2 pieces bolt of steering shaft center

bracket as shown in the illustration.
Symbol Description
D Steering shaft center bracket
bolts
DOIQC37AR11009

STEERING 37A
4. Remove 2 pieces nuts of steering shaft

bracket (nearby key cylinder portion).
Symbol Description
E Steering shaft bracket nuts
DOIQC37AR11010
T
AF
R
D

37A STEERING
T
AF
DOIQC37AR11007
R
D

STEERING 37A
CAUTION
• Instrument under cover removal (Refer to GROUP-52B).
• Instrument under cover Installation (Refer to GROUP-52B).
• Checking steering wheel position with wheels straight ahead
Disassembly steps
1. Special bolt
2. Key lock cylinder
3. Key lock cylinder
4. Steering shaft assembly
5. Steering angel sensor
6. Shaft Joint
T
AF
R
D

37A STEERING

WCH37ASPROC11007
SPECIAL BOLT AND KEY LOCK CYLINDER

REMOVAL
1. If necessary , use a hacksaw to cut the special
bolts at the key lock cylinder bracket.
DOINC37AR08030

SPECIAL BOLT AND KEY LOCK CYLINDER
INSTALLATION
1. When installing the key lock cylinder and key
lock bracket to the column tube, temporarily
T install the key lock cylinder in alignment with

the column boss.
2. Then, tighten the special bolts until the bolt
AF
head is twists off.
Symbol Description
DOINC37AR08031
A Non- reusable parts key lock
cylinder bolt
CAUTION
R
The key lock cylinder brackets and bolts must

be replaced with new part in every new install-
ation.
D

WCH37ASPROC12001
STEERING ANGLE SENSOR

1. Do marking in between the IMS assy and
steering column.
Symbol Description
A IMS assy
B Steering column
C Marking
DOIMC35CR11064

STEERING 37A
2. Remove IMS assy bolt (1 piece).
DOIMC35CR11065
3. Remove IMS assy from steering column.
Symbol Description
A IMS assy
B Steering column
T
AF
DOIMC35CR11066
4. Carefully pry out the steering angle sensor

adaptor from steering angle sensor using
screw driver.
R
D
DOIMC35CR11067
5. Release the steering angle sensor lock using

screw driver
DOIMC35CR11071

37A STEERING
6. Remove steering angle sensor from steering

column.
Symbol Description
D Steering angle sensor
DOIMC35CR11068

STEERING ANGLE SENSOR
1. Install steering angle sensor into steering
column.
NOTE
T
Ensure that the steering angle sensor connector
facing toward the steering column as shown in
the illustration.
AF
DOIMC35CR11069
2. Press in steering angle sensor adaptor slowly

into steering angle sensor.
R
D
DOIMC35CR11070
3. Install IMS assy into steering column and

tighten the bolt (1 piece).
NOTE
Ensure that the marking between IMS assy
and steering column is align as shown in the
illustration.
Symbol Description
A IMS assy
B Steering column
C Marking
DOIMC35CR11064

STEERING 37A
STEERING LINKAGE / 29
STEERING LINKAGE WCH37ASASSY11009
T
AF
R
DOIQC37AR11011
D
CAUTION

37A STEERING
/ 30 STEERING LINKAGE
• Power steering fluid draining (Refer to GROUP-37A - On-Vehicle Service.)
• Check the dust cover for cracks or damage.
• Power steering fluid supplying (Refer to GROUP-37A - On-Vehicle Service.)
• Checking steering wheel position with wheels straight ahead.
• Front wheel alignment adjustment (Refer to GROUP-33A).
• Under cover (Refer to GROUP-032).
Removal steps
1. Split pin
2. Tie-rod end
3.Tube assy,return (G)
4.Hose assy, pressure
5.Tube assy cooler
6.Steering linkage
7.Sub frame assy
T1: 0.9 - 1.4 kgm (9 - 14 Nm, 6.51 - 10.13 ft.lbs)
T2: 1.2- 1.8 kgm (12- 18 Nm, 8.68- 13.02 ft.lbs)
T3: 3.5 - 4.5 kgm (35 - 45 Nm, 25.32 - 32.55 ft.lbs)
T
T4: 4.5 kgm (45 Nm, 32.55 ft.lbs)± 0.5 kgf.m
T5: 2.0 - 3.4 kgm (20 - 34 Nm, 14.47 - 24.59 ft.lbs)
T6: 1.5 - 2.0 kgm (15 - 20 Nm, 10.85 - 14.47 ft.lbs)
AF
R
D

STEERING 37A
TIE-ROD END DISCONNECTION
Symbol Description
A Nut
CAUTION
(1) By using the special tool, loosen the tie rod
end mounting nut. Only loosen the nut. Do
not remove it from the ball joint.
(2) Support the special tool with a cord or etc.
DOIIC37AR9021
STEERING LINKAGE TOTAL PINION TORQUE

Using the special tools, rotate the pinion gear at
the rate of one rotation in approximately 4 to 6
seconds to check the total pinion torque
Standard value: 0.06–0.12 kgf.m
Change in torque: 0.029 kgf.m
T CAUTION
The power steering gear box assembly should
be secured at the mounting sections. If it is se-
AF
cured in any other places, the gear housing may
become deformed or damaged.
DOIIC37AR9038
NOTE
When measuring, remove the bellows from the
rack housing. Measure the pinion torque through
the whole stroke of the rack. If the measured
R
valve is not within the standard range, first adjust

he rack support cover, and then check the total
pinion starting torque again.
D
CHECK THE BALL JOINT FOR SWING ANGLE .

1. Minima joint capability swing angle of tie
rod must be ± 30 min. Swing Torque :0.49 –
2.45 kgf.m
2. Measure after 10 times swing.
3. Initial rotating torque : 8.82 kgf.m maximum.
4. Even if the measured valve is below the
standard value, the tie rod which swings
smoothly without excessive play may be used.
Symbol Description
B 28 °(minimum)
DOINC37AR08019

37A STEERING
OUTER BALL JOINT

1. Measure the tie rod angle. The value shall
lower than the standard value. Then check
the tie rod angle ball joint turning condition.
Symbol Description
A 25°(minimum)
DOINC37AR08020
BELLOWS STEEL BAND INSTALLATION

1. Turn the adjusting bolt of the special tool to
adjust the opening dimension (C) to the
standard value.
< When more (C) : 2.9 mm >
T
Screw in the adjusting bolt.
< When less than 2.9 mm >
Loosen the adjusting bolt.
AF
NOTE
1.1 The dimension (C) is adjusted by approx-
imately, 0.3 mm per one turn.
DOIHC37AR05009
1.2 Do not turn the adjusting bolt more
than one turn.
Symbol Description
R
A Stopper
B Adjusting screw
C Standard value
D
2. Use the shown illustration to crimp the bel-

lows steel band.
CAUTION
(1) Do not hold the bellow during clamping.
(2) Hold the rack housing and use the spe-
cial tool to crimp the bellows steel band
securely.
(3) Crimp the bellows steel band until the
special tool touches the stopper.
STEERING LINKAGE REMOVAL

DOIHC37AR05010 CAUTION
Be careful not to damage the bellows and the
tie-rod end dust cover when removing the gear
box assembly.
INSPECTION
Check the rubber parts for cracks and breakage.

STEERING 37A
1. Marking (A) the steering shaft as shown in

the illustration.
Symbol Description
A Marking
B Steering shaft
DOINC37AR08026
2. Remove 1 piece bolt at steering shaft end

portion ( connection between steering link-
age and steering shaft)
Symbol Description
C Steering shaft end portion bolt
T
AF
DOIQC37AR11008
3. Remove 2 pieces nuts bracket return G tube

assy and pressure hose .
R
Symbol Description
D bracket return G tube assy and
pressure hose
D
DOIQC37AR11012
4. Disconnect return G tube assy and pressure

hose assy from steering linkage.
Symbol Description
E Return G tube assy
F Pressure hose assy
DOIQC37AR11014

37A STEERING
5. Remove 2 pieces bolt (RHS) of steering link-

age clamp as shown in the illustration.
Symbol Description
G Steering linkage clamp
DOIQC37AR11015
6. Remove another 2 pieces bolt (LHS) of steer-

ing linkage as shown in the illustration.
7. Slowly and carefully pull the steering linkage
from right hand side of the vehicle as shown
Symbol Description
T H Steering linkage
AF
R
D
DOIQC37AR11013

STEERING 37A
T
AF
R
DOINC37AR08021
CAUTION
D
– Non-reusable parts
Disassembly steps
1. Tie rod end and locking nut
2. Clip
3. Bellows
4. Band
5. Tie rod
6. Steering linkage
T1: 3.5 - 4.5 kgm (35 - 45 Nm, 25.32 - 32.55 ft.lbs)

37A STEERING
LUBRICATION AND SEALING POINT
T
AF
R
D
DOINC37AR08022

STEERING 37A
CAUTION
– Grease
T
AF
R
D

37A STEERING
/ 38 POWER STEERING OIL PUMP
POWER STEERING OIL PUMP WCH37ASASSY11011
REMOVAL AND INSTALLATION (ENGINE CFE)
T
AF
R
DOIQC37AR11017
D
• Power steering fluid draining (Refer to Module 1.8 GROUP 37A – On Vehicle Service ).
• Power steering fluid supply (Refer to Module 1.8 GROUP 37A – On Vehicle Service ).
• Fead belt removal and installation (Refer to Module 1.2 GROUP 016 ).
• Power steering fluid line bleeding (Refer to Module 1.8 GROUP 37A – On Vehicle Service ).
Removal steps
1. Fead belt
2. Bolt
3. Oil pump
4. Clip
5. Suction hose assy
6. Pressure hose
T1: 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T2: 1.2 - 1.8 kgm (12 - 18 Nm, 8.68 - 13.02 ft.lbs)

STEERING 37A
POWER STEERING OIL PUMP / 39
POWER STEERING OIL PUMP

REMOVAL AND INSTALLATION (ENGINE IAFM)
T
AF
R
DOIQC37AR11018
D
• Power steering fluid draining (Refer to Module 1.8 GROUP 37A – On Vehicle Service ).
• Power steering fluid supply (Refer to Module 1.8 GROUP 37A – On Vehicle Service ).
• Fead belt removal and installation (Refer to Module 1.2 GROUP 016 ).
• Power steering fluid line bleeding (Refer to Module 1.8 GROUP 37A – On Vehicle Service ).
Removal steps
1. Fead belt
2. Bolt
3. Oil pump
4. Clip
5. Suction hose assy
6. Pressure hose
T1: 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T2: 1.2 - 1.8 kgm (12 - 18 Nm, 8.68 - 13.02 ft.lbs)

37A STEERING
/ 40 POWER STEERING HOSES
POWER STEERING HOSES WCH37ASASSY11012
T
AF
R
DOIQC37AR11016
D
• Power steering fluid draining ( Refer to Module 1.8 GROUP 37A – On Vehicle Service ).
• Power steering fluid supply ( Refer to Module 1.8 GROUP 37A – On Vehicle Service ).
Removal Steps
1. Hose suction
2. Reservoir ,oil assy
3. Hose, return (R)
4. Hose assy, pressure
5. Tube assy return (G)
6. Tube asssy ,cooler
7. Power steering pump
T1: 0.9 -1.4 kgm (9 -14 Nm, 6.51 -10.13 ft.lbs)
T2: 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.2
T3: 1.2 1.8 kgm (NaN NaN NaN Nm, NaN NaN NaN ft.lbs)
T4: 1.5 - 2.5 kgm (15 - 25 Nm, 10.85 - 18.08 ft.lbs)
T5: 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T6: 0.4 - 0.6 kgm (4 - 6 Nm, 2.89 - 4.34 ft.lbs)
T7: 0.5 - 0.6 kgm (5 - 6 Nm, 3.62 - 4.34 ft.lbs)

STEERING 37A
POWER STEERING HOSES / 41
TUBE ASSY RETURN G REMOVAL

WCH37ASPROC11009
1. Remove 2 pieces nuts bracket tube assy re-

turn G and pressure hose .
Symbol Description
A Bracket tube assy return G and
pressure hose.
DOIQC37AR11019
2. Disconnect tube assy return G and pressure

hose assy from steering linkage.
Symbol Description
B Tube assy return G
C Pressure hose assy
T
AF
DOIQC37AR11020
3. Loosen 1 piece bolt of tube assy cooler

4. Remove clip at tube assy cooler
R
Symbol Description
D Tube assy cooler
E Clip
D
DOIQC37AR11021

37A STEERING
/ 42 POWER STEERING HOSES
NOTE
T
AF
R
D

BODY 42
Content /1
42 BODY
SPECIFICATIONS ....................................................................... 42/4
SEALANT AND ADHESIVE ........................................................ 42/4
DOOR .................................................................................. 42/4
SPECIAL TOOLS ........................................................................ 42/5
HOOD ................................................................................... 42/6

FENDER ................................................................................. 42/9

SPLASH SHIELD ........................................................................ 42/11

FRONT SPLASH SHEILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42/11
REAR SPLASH SHEILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42/13
REAR SPLASH SHEILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42/13
FUEL FILLER DOOR ...................................................................

T 42/14
42/14
AF
FUEL FILLER DOOR LOCK HOOK ASSEMBLY REMOVAL ..................... 42/16
FUEL FILLER DOOR LOCK HOOK ASSEMBLY INSTALLATION ................ 42/16
WINDOW GLASS ..................................................................... 42/17

WINDOW REPAIR ................................................................... 42/17
R
HANDLING OF AUTO WINDOW SEALER ....................................... 42/18

BODY PINCH-WELD FLANGE SERVICING ....................................... 42/18
WORKING PROCESS ................................................................ 42/19
D
WINDSHIELD ........................................................................... 42/20

REMOVAL AND INSTALLATION SERVICE POINTS ............................. 42/22
REAR GLASS ............................................................................ 42/25

SERVICE POINT OF REPAIR ........................................................ 42/29
REAR GLASS SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42/29
DOOR .................................................................................... 42/34

DIAGNOSIS FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42/34
DOOR ASSEMBLY ..................................................................... 42/36

FRONT DOOR TRIM ................................................................... 42/40

42 BODY
/2 Content

REAR DOOR TRIM ..................................................................... 42/43

TRUNK LID .............................................................................. 42/46

REMOVAL SERVICE POINT .......................................................... 42/48

TORSION BAR TRUNK LID REMOVAL ........................................... 42/48
STRIKER TRUNK LID ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42/49
FRONT DELTA COVER ................................................................. 42/50

REAR DELTA COVER .................................................................. 42/52

FRONT WINDOW GLASS AND REGULATOR .....................................

T 42/54
42/54
AF
HOOD ................................................................................... 42/55
SPECIAL TOOLS ...................................................................... 42/55
REAR WINDOW GLASS AND REGULATOR ....................................... 42/56

FRONT END MODULE ................................................................ 42/57

R

DIASSEMBLY AND REASSEMBLY ................................................. 42/58
DOOR HANDLE, LOCKING MODULE AND LATCH ............................... 42/59

D
FRONT DOOR ........................................................................ 42/59

REAR DOOR .......................................................................... 42/60
WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP ... 42/61


BODY 42
Content /3
NOTE
T
AF
R
D

42 BODY
/4 SPECIFICATIONS
Hood
Type Rear hinged, front opening type
Front door
Construction Front-hinge
Regulator system Scissor type
Rear door
Construction Front-hinge
Regulator system Wire type
Trunk lid
Type Inner-hinged, with gas damper
Glass installation method
Windshield 4.8 mm (0.19 in)
Rear window glass 3.2 mm (0.13 in)
Front door glass
Rear door glass
T 3.1 mm (0.12 in)

3.1 mm (0.12 in)
AF
Power window motor
Revolutions under no load 94 r/min or more
Revolutions under load
At 0.3 kgm (3 Nm, 2.17 ft.lbs) (0.3 kgm (3 Nm, 2.17 54-74 r/min
ft.lbs))
Bound current 21 A
R
Direct of rotation Clockwise and counterclockwise

Power window relay
Maximum contact current 20 A
D
Rated coil current 0.2 A

Door lock actuator
Bound current (at12 V) 4.2-6.2 A
Operating voltage range 9-15 V
Tripping time* ( at 12 V) 5-30 V
NOTE
*Tripping time is the time consumed until current reaches 0.5 A after power connection.
SEALANT AND ADHESIVE
Items Specified sealant and adhesive Remarks
Splash shield to fender – –
3M ATD Part No. 8609 Super Fast Ureth-
Windshield –
ane Auto Glass sealant or equivalent
DOOR
Door outside handle play 7.8 mm (0.31 in)

BODY 42
SPECIAL TOOLS /5

Door inside handle play 8.6 mm (0.34 in)
Removal of switch
MB990784 Ornament remover
trim etc.
DOIIC042R9001
Removal and in-

stallation of wind-
MB990480 Glass holder
shield and trunk
lid glass
DOIIC042R9002
T
AF
R
D

42 BODY
/6 HOOD
HOOD WCH042SASSY11002
T
AF
R
D
DOIQC042R11001

BODY 42
HOOD /7

• Front Deck Garnish (Refer to GROUP 51- Front Deck Garnish)
Removal Steps
• Splash shield <Driver's side>
1. Hood lock release cable assy (Cable and Handle release)
2. Cable 1
Hood Lock Release
3. Cable 2
4. Latch assy hood
Hood and Hood Hinge
5. Rod hood support
6. Hood hinge
7. Adjustable damper
8. Fix damper
9. Weatherstrip hood
10. Seal hood front
11. Seal hood front 2
12. Hood
T1 : 0.7 - 1.1 kgfm
T
AF
R
D

42 BODY
/8 HOOD
HOOD LATCH ASSY REMOVAL

WCH042SPROC11001
1. Use the special tool pull out the centre pin

in the clip and then remove the clip
Symbol Description
A Pin
B Clip
DOIQC042R11027
2. Remove the latch assy bolt as shown in the

illustration.
T
AF
DOIQC042R11016
3. Release the hood cable.
Symbol Description
R
A Latch assy
B Hood cable 1
D
DOIQC042R11017
ADJUSTMENT DAMPER
During installing the damper, turn and adjust
the damper until the height is approximately
13.3 mm (0.52 in).
Symbol Description
A Damper
Damper height 13.3 mm
B
(0.52 in)
C Body surface
DOINC042R09067

BODY 42
FENDER /9
FENDER WCH042SASSY11003
T
AF
R
DOIQC042R11002
D
Pre-removal and Post-Installation operation

• Front Bumper Removal and installation (Refer to GROUP 51– Front Bumper).
• Front Deck Garnish Removal and installation (Refer to GROUP 51– Front Deck Garnish ).
• Front Delta Cover Removal and installation (Refer to GROUP 51– Front Delta Cover).
• Splash Shield Removal and installation (Refer to GROUP 51– Splash Shield).
• Wiper arm and blade Removal and installation ( Refer to GROUP 51 – Wiper arm and blade ).
Removal steps Fender
1. Bolt flange
2. Side support front bumper
3. Front fender barrier and clip trim
4. Front fender panel

42 BODY
/ 10 FENDER
FENDER ASSY REMOVAL

1.
DOIQC042R11019
Removal bolts (7 pieces).
T
AF
DOIQC042R11018
2. Remove lower bolt as shown in illustration.

R
D
DOIQC042R11020
3. Remove fender from body.
Symbol Description
A Fender
DOIQC042R11021

BODY 42
SPLASH SHIELD / 11
SPLASH SHIELD WCH042SASSY11004

FRONT SPLASH SHEILD
T
AF
R
DOIQC042R11003
D

42 BODY
/ 12 SPLASH SHIELD

• Front Bumper Removal and installation (Refer to GROUP 51– Front Bumper).
Removal steps front splash shield
1. Nut flange
2. Bolt flange
3. Clip trim
4. Front splash shield
T1 : 0.7 - 1.1 kgm (7 - 11 Nm, 5.06 - 7.96 ft.lbs)
T
AF
R
D

BODY 42
SPLASH SHIELD / 13
REAR SPLASH SHEILD
T
AF
R
DOIQC042R11011

• Rear Bumper Removal and installation (Refer to GROUP 51– Front Bumper).
D
Removal steps Rear splash shield

1. Bolt flange
2. Grommet screw
3. Screw tapping
4. Clip trim
5. Rear splash shield
T1 : 0.7 - 1.1 kgm (7 - 11 Nm, 5.06 - 7.96 ft.lbs)

42 BODY
/ 14 FUEL FILLER DOOR
FUEL FILLER DOOR WCH042SASSY11005
T
AF
R
D
DOIQC042R11004

BODY 42
FUEL FILLER DOOR / 15

• Front Seat and Rear Seat side back (Refer to GROUP - 52A)
• Front Scuff Plate and Rear Scuff Plate (Refer to GROUP - 52A)
• Rear pillar trim (Refer to GROUP - 52A)
• Trim center pillar lower (Refer to GROUP - 52A)
Removal steps
1. Fuel filler door panel assembly
2. Fuel filler door lock hook assembly
3. Fuel filler door lock release cable
4. Lid lock release handle
5. Tape Rhd
6. Tape Lhd
7. Clip two cable
8. Latch assy trunk lid
T1 : 0.7 - 1.1 kgm (7 - 11 Nm, 5.06 - 7.96 ft.lbs)
T
AF
R
D

42 BODY
FUEL FILLER DOOR LOCK HOOK

ASSEMBLY REMOVAL
1. Use screw driver and pry out the fuel filler
door lock hook.
Symbol Description
A Fuel filler door lock hook
B Screw Driver
DOIQC042R11028
FUEL FILLER DOOR LOCK HOOK

ASSEMBLY INSTALLATION
1. Ensure the stud guide(A) facing out.
Symbol Description
A Fuel filler door lock hook
T C Stud
AF
DOIQC042R11029
R
D

BODY 42
WINDOW GLASS / 17
WINDOW GLASS WCH042SPROC12002
WINDOW REPAIR
The following glass sections are installed by means of a liquid urethane adhesive method.
• Winshield
• Trunk lid window glass
T
AF
R
D
DOIMC042R07103
• Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
Primer: 3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
• Auto Window Sealer Kit TEROSON- 127, 37 V
1. Sealer
2. Nozzle
3. Primer container cap
4. Primer container
5. Piano wire
6. Brush
7. Cleaner
8. Primer
9. Filter Gauge
10. Instruction manual
11. Instruction manual
NOTE
When using TEROSON-127, 37 V, Follow the instructions of the manual included in the kit

42 BODY
/ 18 WINDOW GLASS
Additional material required

Spacers Available as service part
Dam Available as service part
Anti-rust solvent (or Tectyl 506T.......Valvoline Oil Com- For rust prevention
pany) For grease removal from bonded surface
Isopropyl alcohol Dia. x length ....... 0.6 mm (0.024 in) x 1
Steel piano wire mm (0.039 in)
For cutting sealant
For pressing-out sealant
HANDLING OF AUTO WINDOW SEALER
Keep the sealant in a cool place, not exposed to the direct rays of the sun.
Do not place any heavy article on the sealant nor press it, otherwise it will become deformed.
Avoid storing the sealant for more than 6 month, because it will lose its sealing effect.
BODY PINCH-WELD FLANGE SERVICING
Before servicing the body pinch-weld flange, remove old sealant completely.
If the flange requires painting, bake it after painting is completed.
T
AF
R
D

BODY 42
WINDOW GLASS / 19
WORKING PROCESS
The following glass sections are installed by means of a liquid urethane adhesive method.
T
AF
R
D
DOINC042R08030

42 BODY
/ 20 WINDSHIELD
WINDSHIELD WCH042SASSY11006
T
AF
R
D
DOIQC042R11005

BODY 42
WINDSHIELD / 21

• Front Deck Garnish (Refer to GROUP – 51).
• Front Pillar Trim Removal and installation (Refer to GROUP – 52A ).
• Headlining Removal and Installation (Refer to GROUP – 52A ).
Removal steps
1. Glass Windshield
2. Glass stopper
3. Dam seal window assy
T
AF
R
D

42 BODY
/ 22 WINDSHIELD

POINTS WCH042SPROC11005
WINDSHIELD REMOVAL
1. In order to protect the body (paint surface),
apply cloth tape to all body areas around the
installed windshields glass.
2. Using a sharp-point drill, make hole in the
windshield glass adhesive.
3. Pass the piano wire from the inside of the
vehicle through the hole.
4. Pull the piano wire alternately from the in-
DOIQC042R11030
side and outside along the windshield glass
to cut the adhesive.
CAUTION
Do not let the piano wire touching the edge
of the windshield glass.
5. Make mating marks on the windshield glass
and body.
T 6. Use the special tool to remove the windshield

glass.
AF
R
DOIQC042R11031
D
7. Use a knife to cut out the remaining adhesive

so that the thickness is within 2 mm (0.079
in) around the entire circumference of the
body flange.
8. Finish the flange surfaces so that they are
smooth.
CAUTION
(1) Be careful not to remove more adhesive
than is necessary.
(2) Be careful also not to damage the
paintwork on the body surface with the
knife. If the paintwork is damaged, re-
DOIIC042R9021
pair the damaged area with repair paint
or anti-rust agent.
9. When reusing the glass, remove the adhesive
still adhering to the glass, and clean with
isopropyl alcohol.
10. Clean the body side in the same way.

BODY 42
WINDSHIELD / 23
CAUTION
Let the cleaned surfaces stand for 3 minutes
or more, and carry out the next procedures
after they have dried. Also, do not touch the
surface that has been cleaned.

WINDSHIELD RUBBER DAMPER/WINDSHIELD
GLASS STOPPER/WINDSHIELD GUIDE
PIN/WINDSHIELD INSTALLATION
1. When removing and reinstalling the glass,
temporarily place a mating mark at rubber
damper and guide pin on the glass as shown
Symbol Description
A Rubber damper/guide pin
DOINC042R09049
B Mating mark
C Windshield
T D Guide pin
2. Use isopropyl alcohol to degrease the inside
AF
and outside of the windshield glass and the
body flanges.
3. Soak a sponge in the primer, and apply
evenly to the glass and the body in the spe-
cified places.
4. Apply the primer, on the available path and
then let it dry for 3 to 30 minutes.
R
CAUTION
(1) The primer strengthens the adhesive, so
be sure to apply it evenly around the
D
entire circumference.Do not touch the

coated surface.
5. Attach the rubber damper and guide pin in
the specified positions so that there are no
bends or lifts on the inside of the windshield.
6. Attach the glass stopper so that the clearance
at both left and right will be the same during
installation.
7. Install the windshield moulding.
8. Apply beta seal.

42 BODY
/ 24 WINDSHIELD
9. Fill-in adhesive in a sealant gun. Then apply

the adhesive on the 'DOT' mark around the
windshield.
Adhesive thickness (T1) :12.0 mm (0.47 in)
Symbol Description
a Adhesive
b Panel side outer
c Front pillar lower reinforce-
ment
d Front piller inner upper
DOINC042R09050
e Ceramic line
f 'DOT' mark
10. Align the mating marks on the glass and the
body, and lightly press the windshields glass
evenly so that it adheres completely.
11. Use a spatula to remove any excessive adhes-
ive. Then, clean the surface with isopropyl
T
alcohol.
12. Wait 30 minutes or more, and then test for
water leakage.
AF
CAUTION
(1) Do not move the vehicle unless abso-
lutely necessary.
(2) When testing for water leakage, do not
pinch the end of the hose to spray the
water.
R
D

BODY 42
REAR GLASS / 25
REAR GLASS WCH042SASSY11007
T
AF
R
D
DOIQC042R11006

42 BODY
/ 26 REAR GLASS

• Rear Pillar Trim Removal and Installation (Refer to Group 52A -Trims)
• Headlining removal and Installation (Refer to Group 52A -Trims)
Removal steps
1. Terminal electric gnd
2. Defogger harness
3. Rear Glass
4. Spacer glass
5. Dam rear glass
6. Guide /locator pin
T
AF
R
D

BODY 42
REAR GLASS / 27
REAR GLASS REMOVAL

1. Remove the high mounted stop lamp
mounting screw (2 pieces).
Symbol Description
A High mounted stop lamp
DOIQC042R12001
2. Disconnect high mounted stop lamp connect-

or.
Symbol Description
B High mounted stop lamp con-
nector
T
AF
DOIQC042R12002
3. Disconnect rear defogger connector (RH and

LH side).
R
Symbol Description
C Defogger connector
D
DOIQC042R12003
4. In order to protect the body paint surface,

apply masking tape to all body areas around
the rear glass.
Symbol Description
D Masking tape
DOIQC042R12004

42 BODY
/ 28 REAR GLASS
5. Before removing the rear glass, mark an ar-

row on top of the roof in order to align the
glass locator.
Symbol Description
E Arrow marking
H Glass locator
NOTE:
During installation, use the arrow marking
as a guide for rear glass fixation.
T
AF
DOIQC042R12005
6. By using a sharp tool, make a hole in the rear

glass adhesive.
7. Pass the piano wire from inside of the vehicle
R
through the hole.
Symbol Description
D
I Sharp tool
J Piano wire
DOIQC042R12006

BODY 42
REAR GLASS / 29
8. Pull the piano wire from the inside and out-

side along the rear glass in order to cut the
adhesive.
CAUTION:
Do not let the piano wire touch the edge of
the rear glass.
DOIQC042R12007
9. Use the special tools MB990480 to remove

rear glass.
T
AF
DOIQC042R12008
SERVICE POINT OF REPAIR

REAR GLASS SERVICE POINT
R
1. Cover cabin with paper.
Symbol Description
K Paper
D
DOIQC042R12009
2. Use a knife to cut away the remaining adhes-

ive so that the thickness is within 2 mm
around the entire circumference of the body
flange.
Finish the flange surfaces so that they are
smooth.
Symbol Description
L Knife
(1) Be careful do not to damage the paint-
work on the body surface with the knife.
If the paintwork is damaged, repair the
DOIQC042R12010

42 BODY
/ 30 REAR GLASS
damaged area with repair paint or anti-

rust agent.
3. When reusing the glass, use a gasket scraper
to scrape away the remaining adhesive of
the rear glass.
Symbol Description
M Scraper
DOIQC042R12011
4. Wipe and clean the glass surface with a rag

moistened with isoproply alcohol.
T
AF
DOIQC042R12012
R
D

BODY 42
REAR GLASS / 31

REAR WINDOW GLASS INSTALLATION
1. Install the glass locator at 2 locations as
Symbol Description
N Glass locator
2. Install the glass spacer at 5 location as shown
Symbol Description
O Glass spacer
Spacer dimension:
Height 5.2 ± 0.5 mm
Width 5 mm
Length 50 mm
T
AF
DOIQC042R12013
3. Install rear glass rubber damper around the

entire circumference of the rear glass.
R
Symbol Description
P Rubber damper
D
DOIQC042R12014

42 BODY
/ 32 REAR GLASS
4. Stir glass primer or body primer with brush.
Symbol Description
P Glass primer or body primer
5. Apply the primer with brush to the “BODY”.
Specified Glass primer:
SUNSTAR 435 – 40T YOKOHAMA GOMU GS-
78 or equivalent.
6. Apply the primer with brush to the “REAR

GLASS”.
Specified body primer:
SUNSTAR 435– 98 YOKOHAMA GOMU RC-
50E or equivalent.
7. After applying the primer, let it dry for 3 to

30 minutes.
CAUTION:
(1) The primer strengthens the adhesive
strength, so be sure to apply it evenly
T around the entire circumference. Also, a

too thick application will cause lowering
of adhesive strenght.
AF
(2) Do not touch the coated surface.
DOIQC042R12015
8. Within 30 minutes after applying the primer,

apply adhesive evenly around the entire cir-
cumference of the rear glass.
R
Symbol Description
R Nozzle tip
D
S Adhesive
NOTE:
Cut the nozzle tip of sealant gun into a V
shape to simplify adhesive application.
Specified adhesive:
SUNSTAR PENGUIN SEAL 556 or equivalent.
DOIQC042R12016

BODY 42
REAR GLASS / 33
9. Remove the paper cover.
Symbol Description
T Paper
DOIQC042R12017
10. After applying the adhesive, use the special

tools MB990480 to install the rear glass.
11. Aim and align the glass locator at the arrow
marking on the roof mark.
Symbol Description
H Arrow marking
T I Glass locator
12. After installing the rear glass to the body,
AF
let it stand for 30 minutes or more. Then,
test for water leakage.
CAUTION:
(1) If moving the vehicle, it should be done
gently.
(2) When testing for water leakage, do not
pinch the end of the hose to spray the
R
water.
D
DOIQC042R12018
13. Connect rear defogger connector (RH and

LH side).
Symbol Description
C Defogger connector
DOIQC042R12003

42 BODY
/ 34 DOOR
14. Connect high mounted stop lamp connector.
Symbol Description
B High mounted stop lamp con-
nector
DOIQC042R12002
15. Install the high mounted stop lamp and

tighten the mounting screw (2 pieces).
Symbol Description
A High mounted stop lamp
T
AF
DOIQC042R12001
DOOR WCH042TSHOT12001
R
TROUBLESHOOTING
DIAGNOSIS FUNCTION
INPUT SIGNAL INSPECTION<VEHICLE WITH BCM>
D
1. Connect the PADT-07 to the diagnosis connector (refer to GROUP 00 - How to Use Troubleshoot-
ing/Inspection Service Point
2. If buzzer of the PADT-07 sounnds once when door lock actuator switch is operated (LOCK/UNLOCK),
the BCM input signal for that switch system is normal.
INSPECTION CHART FOR TROUBLE SYMPTOMS <VEHICLE WITH BCM>

BODY 42
DOOR / 35
Trouble symptom Inspection procedure Reference page

The power windows cannot
be operated by any of the 1 WCH042TSHOT013
power window switches.
Driver side power window
cannot be operated by the 2 WCH042TSHOT014
power window main switch.
Passenger's side power win-
dow cannot be operated by
the power window main
3 WCH042TSHOT015
Power windows switch (however, it can be
operated by the power win-
dow sub-switch)
When the glass is raised, it the WCH042TSHOT016
4
lowers automatically
The glass is not iswered when
something is jummed in the 5 WCH042TSHOT017
window
When the glass is fully raised,
it then lowers automatically
None of the door lock func-
T 6 WCH042TSHOT018
AF
tions operate (keyless entry 7 WCH042TSHOT019
system does not operate)
None of the doors lock or un-
lock when the driver's side in-
Door locking
side door locking knob is oper-
mechanism 8 WCH042TSHOT020
ated (including by means of
the door, however keyless
R
entry system operates.

Some doors do not lock or WCH042TSHOT021
9
unlock
D

42 BODY
/ 36 DOOR ASSEMBLY
DOOR ASSEMBLY WCH042SASSY11008
T
AF
R
D
DOIQC042R11007

BODY 42
DOOR ASSEMBLY / 37
• Door adjustment
Front Door (A) Assembly Removal Steps:
1. Door harness connector
2. Door upper hinge
3. Door lower hinge
4. Door assembly
Rear Door (B) Assembly Removal Steps:
1. Door harness connector
4. Door assembly
5. Door upper hinge
6. Door lower hinge
Door Check Removal Steps:
7. Door check
Door Switch Removal Steps:
9. Door switch
Striker Removal Steps:
8. Striker
T1 : 2.0 - 2.9 kgm (20 - 29 Nm, 14.47 - 20.98 ft.lbs)
C : Identification mark
T
AF
R
D

42 BODY
/ 38 DOOR ASSEMBLY
STRIKER
1. Set the striker adjusting marking to the
panel side outer at front door and rear door
Symbol Description
A +1.5 mm
B - 1.5 mm
1 Striker
DOIKC042R07077 2 Adjusting mark at Panel side
outer
DOOR ASSEMBLY
INSPECTION
1. DOOR SWITCH CONTINUITY CHECK
T
Driver's door switch
Symbol Description
A Stroke
AF
4 ON
5 OFF
Terminal No. Continu-
Switch position
ity Check
DOIJC042R04022
Switch position Terminal No. 1 → Con-
R
open (ON) nect No. 3

Depressed (OFF) —
Passenger's door switch
D
Switch position Terminal No

Open (ON) Terminal No. 1→Connect
No. 2
Depressed (OFF) —
Symbol Description
A Stroke
3 On
4 Off
DOIIC042R9040 INSTALLATION SERVICE POINT

1.
DOOR CHECK INSTALLATION

BODY 42
DOOR ASSEMBLY / 39
1. Install the door check . Ensure the identi-

fication mark faces upwards.
Identification
Applicable location
mark
Front door FL
L.H.
Rear door RL
Front door FR
R.H.
Rear door RR
A Front door
B Rear door
C Identification Mark
T
AF
DOIJC042R04020
2.
DOOR LOWER / DOOR UPPER HINGE
INSTALLATION
R
1. The door hinges shape is different accord-

ing to where they are used .Check the
D
identification marks before installation.
Symbol Description
A Front
B Rear
C Identification marks
DOIQC042R11032
Applicable location Identifica-
tion Mark
Front left Upper hinge S1
side door Lower hinge S2
Front right Upper hinge S1
side door Lower hinge S2
Rear left Upper hinge L2
side door Lower hinge L1
Rear right Upper hinge L2
side door Lower hinge L1

42 BODY
/ 40 FRONT DOOR TRIM
FRONT DOOR TRIM WCH042SASSY11009
T
AF
R
DOIQC042R11008
D

• Front delta cover ( Refer to page 42/50 ).
Removal Steps
1. Pull cap handle assy
2. Screw tapping cup handle
3. Pull cap handle switch
4. Bezel assy front
5. Screw tapping bezel assy
6. Screw tapping front door
7. Grommet ,trim
8. Front door trim
9. Inside door handle

BODY 42
FRONT DOOR TRIM / 41
FRONT DOOR TRIM REMOVAL

1. Use the special tool and remove tapping
screw at cup handle assy
Symbol Description
A MB990784–Special tool
DOIQC042R11022
2. Remove bezel assy at front door trim.

3. Disconnect power window switch
Symbol Description
B Power window switch con-
nector
T
AF
R
D
DOIQC042R11024

42 BODY
/ 42 FRONT DOOR TRIM
4. Remove screw tapping front door trim.
T
AF
DOIQC042R11025
5. Release cable from door trim.
Symbol Description
R
C Cable
6. Remove front door trim assy.
D
DOIQC042R11026

BODY 42
REAR DOOR TRIM / 43
REAR DOOR TRIM WCH042SASSY11010
T
AF
R
DOIQC042R11009
D
Removal Steps
1. Pull cap handle assy
2. Screw tapping cup handle
3. Pull cap handle switch
4. Screw tapping rear door trim
5. Grommet trim
6. Rear door trim
7. Inside door handle

42 BODY
/ 44 REAR DOOR TRIM
REAR DOOR TRIM REMOVAL

1. Remove the screws inside handle cover.
DOIQC042R11035
2. Remove screw, then pull the cup handle assy.
Symbol Description
T
AF
DOIQC042R11036
3. Disconnect power window switch.

R
D
DOIQC042R11037
4. Remove 2 pieces screw from door trim.
DOIQC042R11038

BODY 42
REAR DOOR TRIM / 45
5. Release cable and remove rear door trim.
T
AF
DOIQC042R11039
R
D

42 BODY
/ 46 TRUNK LID
TRUNK LID WCH042SASSY11011
T
AF
R
D
DOIQC042R11010

BODY 42
TRUNK LID / 47

• Trunk lid trim ( Refer to GROUP-52A) – Interior
• Trunk lid lamp ( Refer to GROUP-52A) – Interior
• Rear pillar trims ( Refer to GROUP-52A) – Interior
• Rear seat side ( Refer to GROUP-52A) – Interior
• Key assy ( Refer to GROUP-52A) – Interior
• Trunk lid latch cable ( Refer to GROUP-042)-Body
Removal Steps trunk lid panel
1. Fixed damper
2. Adjuster bumper trunk lid
3. Trunk lid lock release cable
4. Trunk lid latch
5. Trunk lid panel
6. Trunk lid release handle
7. Clip torsion bar
8. Torsion bar trunk lid RH
9. Torsion bar trunk lid LH
10. Hinge assy trunk lid
11. Striker trunk lid
T
12. Trunk lid weatherstrip
T1 : 0.7-1.1 kgm (7-11 Nm, 5.06-7.96 ft.lbs)
AF
R
D

42 BODY
/ 48 REMOVAL SERVICE POINT

WCH042SPROC11009
TORSION BAR TRUNK LID REMOVAL

1. Disconnect the body harness and the harness
connector of the rear shelf lower panel.
2. Install the special tool as shown in the illus-
tration, and then remove the torsion bar
from the link while pushing the special tool
downwards. Next, repeat the procedure from
the other side.
CAUTION
Be sure to attach the special tool properly,
as the body or parts could be damaged when
the torsion bar is removed from the special
tool.
Symbol Description
A Clip torsion bar
T B
C
Trunk lid torsion bar
Link
AF
DOIIC042R9008

TORSION BAR TRUNK LID INSTALLATION
R
1. Insert hook end of torsion bar in fixing hole

of hinge RH.
2. Attach torsion bar to double hook of hinge
D
LH.
3. Twist torsion bar and hook to link LH.
4. Insert the end of the torsion bar through the
link side mating hole.
5. Install the special tool in the same way as
when removing the torsion bar, and then
twist the torsion bar while hooking it onto
the link. After this, hook the torsion bar onto
the holder.
CAUTION
Be sure to attach the special tool properly,
as the body or parts could be damaged when
the torsion bar is removed from the special
tool.
Symbol Description
A Trunk lid torsion bar
B Trunk lid torsion bar
DOIIC042R9010
C Link

BODY 42
REMOVAL SERVICE POINT / 49
ADJUSTER BUMPER TRUNK LID

INSTALLATION
Install the bumper as shown in the figure.
Symbol Description
A Adjuster bumper
T
AF
DOIIC042R9011
STRIKER TRUNK LID ADJUSTMENT

1. Check the striker and the latch. If not mesh
R
properly, move the striker forward or back-

ward or to the left or right in order to align
and adjust.
2. Check the clearance of the tailgate when it
D
closed. If the clearance around the tailgate

is not uniform:
2.1 Adjust it by moving the tailgate hinges
forward or backword or to the left or
right until achieving uniform clearance.
DOINC042R09040
WEATHERSTRIP TRUNK LID INSTALLATION

Install the trunk lid weatherstrip by ensuring the
marking (A) is 'UP' position as shown in the illus-
tration.
Symbol Description
A Marking
B Weatherstrip
DOIQC042R12019

42 BODY
/ 50 FRONT DELTA COVER
FRONT DELTA COVER WCH042SASSY11012
T
AF
R
D
DOIQC042R11012

BODY 42
FRONT DELTA COVER / 51
Removal steps
1. Front delta cover
2. Clips
T
AF
R
D

42 BODY
/ 52 REAR DELTA COVER
REAR DELTA COVER WCH042SASSY11013
T
AF
R
D
DOIQC042R11013

BODY 42
REAR DELTA COVER / 53
Removal steps
1. Rear delta cover
2. Clips
3. Seal rear delta cover
T
AF
R
D

42 BODY
/ 54 FRONT WINDOW GLASS AND REGULATOR
FRONT WINDOW GLASS AND REGULATOR WCH042SASSY11014
T
AF
R
DOIQC042R11014
D

• Front door trim removal and Installation (Refer to page 42/40 ).
Removal steps of front door locking module
1. Front door weather film
2. Sash assy front door
3. Regulator from door LH/RH (RHD)
4. Regulator from door LH/RH (LHD)
5. Glass Assy front door
6. Front door LH

BODY 42
HOOD / 55
HOOD WCH042STOOL11002
SPECIAL TOOLS
Removal of switch
trim etc.
DOIIC042R9001
Removal and in-

stallation of wind-
MB990480 Glass holder
shield and tail-
gate glass
DOIIC042R9002
T
AF
R
D

42 BODY
/ 56 REAR WINDOW GLASS AND REGULATOR
REAR WINDOW GLASS AND REGULATOR WCH042SASSY11015
T
AF
R
DOIQC042R11015
D

• Rear door trim removal and Installation (Refer to page 42/43 )
Removal steps of rear door latch assembly
1. Rear door weather film
2. Glass assy rear door window
3. Guide channel rear door window
4. Weatherstrip statinory window LH
5. Glass statinory window LH
6. Runchannel rear door window
7. Regulator assy rear door
8. Rear door

BODY 42
FRONT END MODULE / 57
FRONT END MODULE WCH042SASSY12001
T
AF
R
DOIQC042R11040
D

• Front bumper removal (Refer to GROUP 051 - Exterior).
• Power steering hose ( (Refer to GROUP 37A - Steering ).
• Disconnect head lamp connector (Refer to GROUP 054 – Head Lamp).
• Latch cable (refer to page GROUP 042 - Body).
• Radiator hose (Refer to GROUP 014 - Cooling).
• Section hose (Refer to GROUP 055 - Air cond).
• Cooler hose cooler (Refer to GROUP - 023 – Cvt transmission).
Removal steps
1. Front end module
2. Hood latch
3. Beam assy front bumper
4. Tube assy cooler
T1 : 0.4 - 0.6 kgf.m
T2 : 0.5 - 0.6 kgf.m

42 BODY
/ 58 FRONT END MODULE
DIASSEMBLY AND REASSEMBLY
T
AF
R
DOIQC042R11041
Diassembly and reassembly steps

1. Front end module carrier 8. Pipe assy oil CVT
D
2. Front crash beam assy 9. Hose radiator lower

3. Plate air guide RH /LH 10. Insulator upper
4. Wiring harness front 11. Horn assy(high)
5. Sensor ambient 12. lower air guide
6. Cooling module CVT 13. Hood switch
7. Tube assy cooler 14. Insulator A
T1 : 0.5 - 0.6 kgf.m
T2 : 0.4 - 0.6 kgf.m
T3 : 0.3 - 0.5 kgf.m

BODY 42
DOOR HANDLE, LOCKING MODULE AND LATCH / 59
DOOR HANDLE, LOCKING MODULE AND LATCH WCH042SASSY12002
FRONT DOOR
T
AF
R
DOIQC042R12020
D

• Front door trim removal and Installation (Refer to page 42/40 )
Removal steps of front door locking module
1. Cap passenger out side handle
2. Pad rear
3. Lever handle
4. Pad front
5. Adaptor plate front
6. Latch assy front
7. Check assy front door
8. Door stiker
T1 : 0.7 - 0.9 kgm (7 - 9 Nm, 5.06 - 6.51 ft.lbs)
T2 : 0.7 - 0.9 kgm (7 - 9 Nm, 5.06 - 6.51 ft.lbs)
T3 : 0.7 - 0.9 kgm (7 - 9 Nm, 5.06 - 6.51 ft.lbs)

42 BODY
/ 60 DOOR HANDLE, LOCKING MODULE AND LATCH
REAR DOOR
T
AF
R
DOIQC042R12021
D

• Rear door trim removal and Installation (Refer to page 42/43 )
Removal steps of rear door latch assembly
1. Cap passenger out side handle
2. Pad rear
3. Lever handle
4. Pad front
5. Adaptor plate rear
6. Latch assy rear
7. Check assy rear door
8. Door stiker
T1 : 0.7 - 0.9 kgm (7 - 9 Nm, 5.06 - 6.51 ft.lbs)
T2 : 0.7 - 0.9 kgm (7 - 9 Nm, 5.06 - 6.51 ft.lbs)
T3 : 0.7 - 0.9 kgm (7 - 9 Nm, 5.06 - 6.51 ft.lbs)

BODY 42
WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP / 61
WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP

WCH042SASSY12003
T
AF
R
D
DOIQC042R12022

42 BODY
/ 62 WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP
Removal Steps of beltline moulding

• Door Mirror
2. Beltline moulding
Removal Steps door inner opening weatherstrip
1. Plug
3. Weather film
4. Bumper
5. Door inner opening weatherstrip
Removal Steps door outer opening weatherstrip
• Door check
6. Door outer opening weatherstrip
7. Front door
T
AF
R
D

BODY 42
WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP / 63
REMOVAL AND INSTALLATION WCH042SASSY12004
T
AF
R
D
DOIQC042R12023

42 BODY
/ 64 WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP
Removal Steps of beltline moulding

4. Beltline moulding
Removal Steps door inner opening weatherstrip
1. Plug
2. Weather film
3. Tape buty rubber
5. Bumper
6. Door inner opening weatherstrip
Removal Steps door outer opening weatherstrip
• Door check
7. Door outer opening weatherstrip
8. Rear door
T
AF
R
D

EXTERIOR 51
Content /1
51 EXTERIOR
SPECIFICATIONS ....................................................................... 51/4
SPECIAL TOOL ......................................................................... 51/4

TOOL .................................................................................. 51/4
FRONT BUMPER ....................................................................... 51/5

SERVICE POINT OF REMOVAL .................................................... 51/7
REAR BUMPER ......................................................................... 51/8

LOWER COVER ......................................................................... 51/12
T
GARNISH ................................................................................ 51/13

FRONT DECK ASSY GARNISH REMOVAL AND INSTALLATION ............. 51/13
AF
TRUNK LID GARNISH ASSY REMOVAL AND INSTALLATION ............... 51/14
MOULDING ............................................................................. 51/16

R
SERVICE POINT OF INSTALLATION .............................................. 51/18
TRUNK LID SPOILER ASSY .......................................................... 51/21

D
TRIM CLIP, RUBBER WASHER AND BOTH-SIDED ADHESIVE INSTALLA- 51/22

TION ...................................................................................
TAPE DOOR SASH ..................................................................... 51/26

WINDSHIELD WIPER .................................................................. 51/28

INSPECTION .......................................................................... 51/29
COLUMN SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/29
WIPER MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/30
FRONT WASHER ....................................................................... 51/31

INSPECTION .......................................................................... 51/32
PUMP MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/32

51 EXTERIOR
/2 Content
DOOR MIRROR ASSY ................................................................. 51/33

INSPECTION ......................................................................... 51/39
DOOR MIRROR CONTROL SWITCH CONTINUITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/39
REVERSE WARNING SYSTEM ....................................................... 51/39

INTRODUCTION ..................................................................... 51/39
SPECIFICATIONS ..................................................................... 51/40
SENSOR EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/40
CONTROL UNIT AND BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/40
TROUBLE SHOOTING ............................................................... 51/42
ONE SIDE SENSOR MALFUNCTION CHECKING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/42
IN-CONSISTENT BUZZER BEEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/42
INSTALLATION STANDARD OPERATION PROCEDURE ........................ 51/44
STEP 1: SENSOR DIMENSION AND FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/44
STEP 2: SENSOR AND CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/44
STEP 3: CONTROL UNIT AND BUZZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/45
STEP 4: WIRING AND CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/46
REVERSE SENSOR, CONTROL UNIT AND BUZZER ...............................

T 51/47
51/47
AF
REVERSE WARNING SYSTEM ....................................................... 51/48
REVERSE SENSOR PERFORMANCE ............................................... 51/48
TESTING METHOD AND PROCEDURE ........................................... 51/50
IMPORTANT .......................................................................... 51/51
R
D

EXTERIOR 51
Content /3
NOTE
T
AF
R
D

51 EXTERIOR
/4 SPECIFICATIONS
Windshield wiper motor
Nominal torque 280 kgf.cm
Windshield wiper blade
Wiper angle
Driver's side 83.9°
Passenger's side 86.3°
Wiper blade wiper length
Driver's side 550 mm (21.65 in)
Passenger's side 425 mm (16.73 in)
Windshield washer motor and pump
Motor type Direct current ferrite magnet type
Pump type Centrifugal pump
Pump current 5A
Time of continuous use
With washer fluid
Empty operation
T
Max. 60 sec
Max. 20 sec
AF
Nozzle jet pressure 120 kPa (17.07 psi, 36.23 in.Hg) or more
Tank capacity 2.3 lit (2.42 U.S.qts, 2 Imp.qts)
Intermittent wiper relay
Intermittent interval 8 ± 2 sec
R
Items Standards value

Windshields wiper blade installation position Driver's side A :21 mm (0.83 in)
A1 :45 mm (1.77 in)
D
Passenger's side B :27 mm (1.06 in)

B1 :24 mm (0.94 in)
TOOL
MB990784 Ornament remover Removal of bumper
mounting clips
(front and rear) and
door mirror control
switch
DOIIC051R9001

EXTERIOR 51
FRONT BUMPER /5
FRONT BUMPER WCH051SASSY11006
T
AF
R
DOIQC051R11002
D

• Splash shield clips trim removal and installation (Refer to GROUP 042 – Fender.)
Removal steps
1. Clip trim
2. Screw tapping
3. Clip
4. Bolt M6
5. Front bumper assembly

51 EXTERIOR
/6 FRONT BUMPER
T
AF
R
DOIQC051R11003
Disassembly steps
1. Nut spring 8. Lamp assy front fog LH
D
2. Absorber energy front bumper upper 9. Cover fog lamp RH

3. Mesh front bumper 10. Lamp assy front fog RH
4. Grill garnish 11. Nut speed
5. Top mark 12. License plate support
6. Mesh front bumper lower 13. Nut speed
7. Cover fog lamp LH 14. Front bumper fascia

EXTERIOR 51
FRONT BUMPER /7
SERVICE POINT OF REMOVAL

WCH051SPROC11005
REMOVAL OF CLIP
1. Use the special tool to pull up the centre pin
in the clip.
DOIQC051R11004
2. Remove the clip.
T
AF
DOIQC051R11005
R
D

51 EXTERIOR
/8 REAR BUMPER
REAR BUMPER WCH051SASSY11007
T
AF
R
DOIQC051R11006
D

EXTERIOR 51
REAR BUMPER /9

• Removal and installation of trunk lid opening weatherstrip (Refer to GROUP 042 – Trunk lid.)
Rear bumper assembly removal steps
1. Clip
2. Screw tapping washer
4. Clip
5. Bolt washer
6. Screw tapping
7. Rear bumper assembly
Rear crash beam assembly removal steps
8. Nut
9. Rear crash beam assembly
Central support rear bumper assembly removal steps
10. Bolt washer
11. Central support rear bumper assembly
Side support rear bumper assembly LH removal steps
12. Bolt washer
13. Nut
14. Side support rear bumper assembly LH
Side support rear bumper assembly LH removal steps
15. Bolt washer
16. Nut
T
AF
17. Side support rear bumper assembly RH
R
D

51 EXTERIOR
/ 10 REAR BUMPER
T
AF
R
DOIQC051R11007
Disassembly steps
1. Cover tow eye rear
D
2. Reflector LH
3. Reflector RH
4. Sensor eye LH
5. Sensor eye RH
6. Sensor front cover
7. LIN reverse sensor sub-harness
8. Fascia rear bumper

EXTERIOR 51
REAR BUMPER / 11

WCH051SPROC11006
REMOVAL OF CLIP
1. Use the special tool to pull up the centre pin
in the clip.
DOIQC051R11004
2. Remove the clip.
T
AF
DOIQC051R11005
R
D

51 EXTERIOR
/ 12 LOWER COVER
LOWER COVER WCH051SASSY11008
T
AF
R
DOIQC051R11008
D
Lower cover assembly removal steps

2. Bolt flange
3. Lower cover assembly
T1 : 0.31 kgm (3.1 Nm, 2.24 ft.lbs)
T2 : 0.77 kgm (7.7 Nm, 5.57 ft.lbs)

EXTERIOR 51
GARNISH / 13
GARNISH WCH051SASSY11009
FRONT DECK ASSY GARNISH REMOVAL AND INSTALLATION
T
AF
R
DOIQC051R11009
D

• Removal and Installation of windshield wiper (Refer to 51/28 ).
Removal steps
1. Seal pad RH
2. Seal pad LH
3. Clip
4. Front deck assy garnish

51 EXTERIOR
/ 14 GARNISH
TRUNK LID GARNISH ASSY REMOVAL AND INSTALLATION
T
AF
R
DOIQC051R11010

• Removal and Installation of trunk lid cover.
D
Removal steps
1. Nut cap
2. Trunk lid garnish assy
T1 : 0.71 kgm (7.1 Nm, 5.14 ft.lbs)

EXTERIOR 51
GARNISH / 15

WCH051SPROC11007
TRUNK LID GARNISH ASSY REMOVAL

1. Remove the nut cap (3 pieces).
2. Pull out the trunk lid garnish assy as shown
illustration.
DOIQC051R11011
T
AF
R
D

51 EXTERIOR
/ 16 MOULDING
MOULDING WCH051SASSY11010
T
AF
R
DOIQC051R11012
D
Removal steps
1. Roof drip moulding
Symbol:
a — Tape adhesive (3M RTA 3016)
b — Panel side outer panel
c — Panel roof outer

EXTERIOR 51
MOULDING / 17

WCH051SPROC11008
ROOF DRIP MOULDING REMOVAL

1. Use ornament tool MB990784, slowly and
carefully pry the roof moulding as shown in
the illustration.
NOTE:
The prying process should be started at one
side of the roof moulding until it completely
removed without damaging roof.
DOIQC051R12001
2. Use ornament tool MB990784, carefully re-

move and clean the entire old both-sided
adhesive without scratching the roof surface.
T
AF
DOIQC051R12003
3. Use microfiber cloth to clean the both sided

adhesive residue properly with isopropyl al-
cohol (IPA).
R
D
DOIQC051R12002
Cleaning process for reuse roof moulding:

1. Use ornament tool MB990784, carefully re-
move and clean the entire old both-sided
adhesive without scratching the roof
moulding surface.
DOIQC051R12008

51 EXTERIOR
/ 18 MOULDING
2. Use microfiber cloth to clean roof moulding

surface with isopropyl alcohol (IPA).
DOIQC051R12009
3. Apply 'Primer 3M K520' on the surface area

allocated before installing the both-sided
adhesive.
4. Let the 'Primer 3M K520' dry approximately
2~3 minutes.
T
AF
DOIQC051R12010
5. Properly paste the both-sided adhesive as

Specified both-sided adhesive:
R
3M RTA 301610 mm (0.39 in) wide and 1.6

mm (0.063 in) thick.
D
DOIQC051R12011
SERVICE POINT OF INSTALLATION

ROOF DRIP MOULDING INSTALLATION
1. Apply 'Primer 3M K520' on the surface area
allocated before installing the roof mould-
ing.
2~3 minutes.
DOIQC051R12006

EXTERIOR 51
MOULDING / 19
3. Tear off the both-sided tape backing paper.
DOIQC051R12004
4. Slot the end cap of roof moulding front and

rear to the glass windshield and glass rear.
T
AF
DOIQC051R12005
CAUTION
Ensure end cap properly install as shown in
illustration.
R
D
DOIQC051R11014

51 EXTERIOR
/ 20 MOULDING
5. Firmly press in the roof moulding along to

the roof flange.
DOIQC051R12007
T
AF
R
D

EXTERIOR 51
TRUNK LID SPOILER ASSY / 21
TRUNK LID SPOILER ASSY WCH051SASSY11016
T
AF
R
DOIQC051R11027
D
Removal steps
1. Trunk lid spoiler assy
Symbol description
a : Trim clip
b : Panel trunk lid outer
c : Both-sided adhesive

51 EXTERIOR
/ 22 TRUNK LID SPOILER ASSY
TRIM CLIP, RUBBER WASHER AND BOTH-SIDED ADHESIVE INSTALLATION
T
AF
R
DOIQC051R11030
Removal steps
1. Trunk lid spoiler
D
2. Trim clip
3. Rubber washer
4. Both-sided adhesive C
5. Both-sided adhesive B
6. Both-sided adhesive A

EXTERIOR 51

WCH051SPROC11013
TRUNK LID SPOILER ASSY REMOVAL

1. Use ornament tool MB990784, carefully pry
the trunk lid spoiler assy as shown in the il-
lustration.
NOTE:
The prying process should be started at two
side of the spoiler assy until it completely
removed.
DOIQC051R12012
2. Use ornament tool MB990784, carefully clean

and remove the entire old both-sided adhes-
ive without scratching the trunk lid surface.
T
AF
DOIQC051R12013
3. Use microfiber cloth to clean the adhesive

residue properly with isopropyl alcohol (IPA).
R
D
DOIQC051R12014
Cleaning process for reuse trunk lid spoiler assy:

1. Clean the entire old both-sided adhesive us-
ing ornament tool MB990784 without dam-
aging trunk lid spoiler assy surface.
DOIQC051R12015

51 EXTERIOR
/ 24 TRUNK LID SPOILER ASSY
2. Use microfiber cloth to clean trunk lid spoiler

assy surface with isopropyl alcohol (IPA).
DOIQC051R12016
3. Apply the surface area with 'Primer 3M

K520'.
2~3 minutes.
T
AF
DOIQC051R12017

TRUNK LID SPOILER ASSY INSTALLATION
R
Both-sided adhesive installation:

Properly paste the both-sided adhesive com-
pletely as shown in the illustration.
D
Specified both-sided adhesive:

3M (RTA 3012) 6 mm (0.24 in) wide and 1.2 mm
(0.047 in) thick.
DOIQC051R12018
Trunk lid spoiler assy fitting and finishing pro-

cess to trunk lid :
1. Slightly pull-out the tab tape approximately
1 inch and flip it upwards before fitting trunk
lit spoiler. It is to ensure the tab tape is easy
to pull out after fitting the spoiler to the
trunk lid.
DOIQC051R12019

EXTERIOR 51
2. Install the trunk lid spoiler assy by aligning

the trunk lid spoiler trim clips to the trunk
lid hole.
DOIQC051R12020
3. Slowly pull-out the tab tape while slightly

pressing the spoiler onto the trunk lid for
proper fitting.
T
AF
DOIQC051R12021
4. Slightly press the trunk lid spoiler for good

fitting.
R
D
DOIQC051R12022
5. Check the spoiler gap.

Standard gap:
0.5 mm (0.02 in)
DOIQC051R12023

51 EXTERIOR
/ 26 TAPE DOOR SASH
TAPE DOOR SASH WCH051SASSY11011
T
AF
R
DOIQC051R11016
D
Removal steps
1. Tape door sash front door upper LH/RH
2. Tape door sash front door rear LH/RH
3. Tape door sash rear door upper LH/RH
4. Tape door sash rear door front LH/RH
5. Tape door sash rear door rear LH/RH

EXTERIOR 51
TAPE DOOR SASH / 27

WCH051SPROC11009
TAPE DOOR SASH INSTALLATION

1. Wipe the door sash clean with a rag
moistened with white gasoline.
2. Remove a small portion of the residual adhes-
ive.
3. Tear off the both-sided tape backing paper.
4. Wrap the tape to the door sash properly as
per installation sequence.
Installation Items
sequence
Steps 1 Tape door sash front door
upper LH/RH
Steps 2 Tape door sash front door
rear LH/RH
Steps 3 Tape door sash rear door up-
per LH/RH
T Steps 4 Tape door sash rear door

front LH/RH
AF
Steps 5 Tape door sash rear door rear
LH/RH
DOIQC051R11015
R
D

51 EXTERIOR
/ 28 WINDSHIELD WIPER
WINDSHIELD WIPER WCH051SASSY11013
T
AF
R
DOIQC051R11017
D
Wiper motor and linkage removal steps

1. Shaft cover
2. Washer nut
3. Wiper arm and blade assembly RH
4. Wiper arm and blade assembly LH
6. Wiper link and motor assembly
NOTE
For removal and installation of the column switch assembly (with built-in wiper and washer switch)
(Refer to GROUP 054 — Column switch.)
T1 : 2.3~2.7 kgm (23~27 Nm, 16.64~19.53 ft.lbs)
T2 : 0.7~1.1 kgm (7~11 Nm, 5.06~7.96 ft.lbs)

EXTERIOR 51
WINDSHIELD WIPER / 29

WCH051SPROC11010
WIPER ARM AND BLADE ASSEMBLY

INSTALLATION
1. Installation the wiper blade in the specified
position (wiper blade to the front deck gar-
nish end) as shown in the illustration.
Standard value:
A: 21 mm (0.83 in)
B: 27 mm (1.06 in)
DOIQC051R11018
INSPECTION
COLUMN SWITCH CHECK
Front Wiper and Washer Switch
Switch position Terminal No. Continuity

Check
T OFF
INT
Terminal No.6
Terminal No.6 connect →
Terminal No.9
AF
Wiper
switch Terminal No.7 connect →
1 (LO)
Terminal No.9
DOIQC051R11019
Terminal No.8 connect →
2 (HI)
Terminal No.9
Washer Terminal No.5 connect →
ON
switch Terminal No.9
R
Intermittent Wiper Relay (Intermittent Operation

Inspection)
1. Connect the column switch connect.
D
2. Turn the ignition switch to ACC.

3. Inspect the intermittent operation time when
the wiper switch is turned to INT.
Vehicle with variable intermittent control
FAST : Approx. 2 seconds
SLOW : Approx.15 seconds

51 EXTERIOR
/ 30 WINDSHIELD WIPER
WIPER MOTOR CHECK

Check the wiper motor after disconnecting the
wiring harness connector.
Wiper Motor at Low Speed and High Speed Op-
eration
Connect a battery to the wiper motor as shown
in the illustration and inspection at low speed
and high speed.

Check
Terminal No. 4 connect
Low speed → battery (–)
(ON) Terminal No. 1 connect
Wiper → battery (+)
switch Terminal No. 4 connect
High → battery (–)
speed
(ON) Terminal No. 2 connect
→ battery (+)
T
AF
DOIQC051R11020
Wiper Motor at Stop Position Operation

1. Run the wiper motor at low speed, discon-
nect the battery and stop the motor.
R
2. Make sure mark at the motor shaft rotation.

3. Reconnect the battery as shown in the illus-
tration, and confirm the motor starts turning
D
at low speed it stops at the automatic stop

position.

Check
→ battery (–)
Wiper (Auto Terminal No. 3 connect
switch stop) OFF → battery (+)
→ terminal 5
DOIQC051R11021

EXTERIOR 51
FRONT WASHER / 31
FRONT WASHER WCH051SASSY11014
T
AF
R
DOIQC051R11024
D
Front washer nozzle and tube removal steps

• Windshield wiper removal and installation (Refer to page 51/28 ).
2. Tube link
3. Y-joint
4. Tube nozzle RH
5. L-joint
6. Nozzle RH
7. Tube nozzle LH
8. Nozzle LH
Washer tank removal steps
• Front bumper removal (Refer to 51/5 ).
9. Funnel assy
10. O-ring
11. I-joint
12. Tube tank
13. Washer tank
14. Pump motor
15. Packing pump
T1 : 0.9~1.4 kgm (9~14 Nm, 6.51~10.13 ft.lbs)

51 EXTERIOR
/ 32 FRONT WASHER
PUMP MOTOR CHECK

1. Fill in the washer tank with water.
2. Check that the water squirts out strongly
when battery voltage is applied to terminal
1 and terminal 2.
DOIQC051R11023
T
AF
R
D

EXTERIOR 51
DOOR MIRROR ASSY / 33
DOOR MIRROR ASSY WCH051SASSY11015
T
AF
R
DOIQC051R11025
D
Door mirror assy removal steps

1. Delta cover inner
2. Door mirror assy
Door mirror control switch removal steps
3. Pull cup assy
4. Door mirror control switch

51 EXTERIOR
/ 34 DOOR MIRROR ASSY
T
AF
R
DOIQC051R11026
Door mirror assy disassembly steps

1. Mirror holder assy
D
2. Housing cover
3. Side turn signal assy (Detail procedure to remove and installation Side turn signal assy, refer to
GROUP 054 — Side turn signal lamp)

EXTERIOR 51

WCH051SPROC11012
DOOR MIRROR ASSY REMOVAL

1. Use ornament tool MB990784 to pry out the
delta cover inner as shown in the illustration.
DOIQC051R12024
2. Remove 3 pieces of flange nut as shown in

the illustration.
T
AF
DOIQC051R12025
3. Disconnect the door mirror connector and

remove the door mirror assy.
R
D
DOIQC051R12026
MIRROR HOLDER ASSY REMOVAL

1. Push the door mirror assy backwards as
DOIQC051R12027

51 EXTERIOR
2. Push the top portion of the mirror holder so

that it is slightly tilted as shown in the illus-
tration.
DOIQC051R12028
3. Hold the bottom portion of the mirror holder

and pull it out carefully so that it is released
from all the clamps.
T
AF
DOIQC051R12029
4. Remove the mirror holder.

R
D
DOIQC051R12030
HOUSING COVER REMOVAL

1. Unhook all the clamps to release the housing
cover.
DOIQC051R12031

EXTERIOR 51
2. Remove the housing cover.
DOIQC051R12032

DOOR MIRROR ASSY INSTALLATION
1. Reconnect the harness connector and install
the door mirror assy to the front door.
T
AF
DOIQC051R12026
2. Hold the door mirror assy and tighten 3

pieces of flange nut as shown in the illustra-
tion.
R
D
DOIQC051R12025
3. Install the delta cover.
DOIQC051R12033

51 EXTERIOR
MIRROR HOLDER ASSY INSTALLATION

NOTE:
Clean the body mirror lens, actuator and frame
from glass (lens) splinter before installation.
1. Install the mirror holder by fit the all clamps
to the door mirror housing as shown in the
illustration.
DOIQC051R12034
2. Press the top and bottom portion of the

mirror holder to ensure the clamps is good
locked as shown in the illustration.
T
AF
DOIQC051R12028
3. Reflip the door mirror assy to normal posi-

tion.
R
D
DOIQC051R12035
HOUSING COVER INSTALLATION

Install the housing cover by fit all the clamps to
the door mirror housing as shown in the illustra-
tion.
DOIQC051R12036

EXTERIOR 51
REVERSE WARNING SYSTEM / 39
INSPECTION
DOOR MIRROR CONTROL SWITCH CONTINUITY
CHECK
Operate switch and check for continuity between
terminals.
DOIKC051R07010
Switch position Terminal No. Continuity Check

UP Terminal No. 5 connect → Terminal No.10
Terminal No. 3 connect → Terminal No. 4
DOWN Terminal No. 4 connect → Terminal No.10
Left side
RIGHT Terminal No.4 connect → Terminal No.10
LEFT
TTerminal No.3 connect → Terminal No.11

Terminal No.11 connect → Terminal No.10
AF
UP Terminal No. 9 connect → Terminal No.10
DOWN Terminal No. 4 connect → Terminal No.10
Right side
RIGHT Terminal No. 4 connect → Terminal No.10
R
LEFT Terminal No. 8 connect → Terminal No.10

D
REVERSE WARNING SYSTEM WCH051GINFO11001
INTRODUCTION
The Reverse Warning System (R.W.S.) is an electronic device specially designed to assist you in reverse
your vehicle safely. It consists of 4 zones distance detectors, a control unit and a buzzer.
This high tech ultrasonic sensor system is fitted at the rear bumper and the system is activated
whenever the reverse gear is engaged indicated by a signal audible tone. Ultrasonic signals are gen-
erated and detected by the sensor and based on the time of signal transmitted and received divided
by two depend on the distance from the object. The reverse sensor generated beeping sounds to in-
dicate an object presence within the detecting zones. It detects the object that is within 120 cm (47.24
in) from the rear of the vehicle and covers an angle as wide as 130° (approx.)
WARNING
THE REVERSE SENSOR IS NOT DESIGNED TO BE USED AS SUBSTITUTION FOR THE DRIVER'S EYES OR
TO DIMINISH THE DRIVER'S RESPONSIBILITY WHEN REVERSING THE VEHICLE. THE DRIVER'S IS TO
EXERCISE HIS OWN SKILL AND JUDGMENT AT ALL TIMES.
THE MANUFACTURE SHALL NOT BE UNDER ANY LIABILITY FOR ANY LOSS, DAMAGE OR INJURY AT-
TRIBUTABLE TO ANY DEFECTS, WHETHER DUE TO MATERIALS, WORKMANSHIP OR ANY OTHER
MANUFACTORING DEFECT OF THIS PRODUCT OR OTHERWISE HOWSOEVER CAUSE.

51 EXTERIOR
/ 40 REVERSE WARNING SYSTEM
T
AF
DOIQC051R11029
R
Symbol Description
A Sensor eyes
B Control unit
D
C Buzzer
SENSOR EYE
Power supply 12 V DC
Working voltage 10 V to 16 V DC
Current consumption 20 mA (MAX)
(Operating mode)
Operating temperature -30 °C (-22 °F) to 80 °C (176 °F)
Storage temperature -40 °C (-40 °F) to 90 °C (194 °F)
Operating humidity range Up to 98%
Features of sensor Waterproof
CONTROL UNIT AND BUZZER
Control unit Buzzer

EXTERIOR 51
Voltage 12 V DC ± 3 V DC 12 V DC ± 3 V DC
Operating current < 20 mA < 50 mA
Power consumption 1 W MAX 1 W MAX
No. of channel 2 —
Transmitting frequency 40 ± 2 kHz 2.9 ± 0.5 kHz
200-450 mm (7.87-17.72 Non-stop continous
Zone 1
in) beep
450-700 mm (17.72-27.56 8 beep per second
Zone 2
in)
Detecting range & type of signal
Zone 3
in)
Zone 4
in)
-10 °C (14 °F) to 80 °C -10 °C (14 °F) to 80 °C
Operating temperature
(176 °F) (176 °F)
-15 °C (5 °F) to 90 °C (194 -15 °C (5 °F) to 90 °C
Storage temperature
T
°F) (194 °F)
— 60 — 80 dB (1200 mm
Sound pressure level of buzzer
(47.24 in) in cabin)
AF
Humidity 55 °C (131 °F), 95% for 1 55 °C (131 °F), 95% for
hour 1 hour
CONDITION
R
System malfunction
System malfunction
D
• No beep sound once engage reverse gear

• When solid object at detection zone coverage
State Number State Condition Next state

Check installation NG Re-connect
2 • Correct wire connection
• Wire connection loose OK go to 3
Replace car battery if
NG
3 Check car battery supply voltage is below 9 V
OK go to 4
Check car back-up or reverse NG Replace
• Car battery supply
4
• Wire connection OK go to 5
• Fuse for reverse light
NG Replace
5 Check buzzer condition
OK go to 6
Check left / right sensor condi- NG Replace
6
tion OK go to 7

51 EXTERIOR

Replace reverse sensor control
7
unit
TROUBLE SHOOTING WCH051TSHOT11002
ONE SIDE SENSOR MALFUNCTION CHECKING METHOD

CONDITION
System malfunction
System malfunction
• No good right hand sensor
State Num-
State Condition Next state
ber
Check wire connection NG Re-connect
2 • Loose OK go to 3
3
Interchange
• Left /right sensor connection
Sensor Function
T OK
NG
go to 4
go to 6
AF
4 Right hand OK NG go to 5
Left hand OK
5 Replace Reverse sensor control unit OK Stop
Sensor Function
6 Right hand NG NG go to 7
R
Left hand OK
7 Replace right hand sensor OK Stop
D
IN-CONSISTENT BUZZER BEEP WCH051TSHOT11003
CONDITION
Inconsistent buzzer beep
Inconsistent buzzer beep
• No object within detection zones

Check surrounding for any interfer- Remove from inter-
NG
2 ence ference object
OK go to 3
Check system NG Repair
3 • Installation
• Wire connection OK go to 4
Check buzzer for faulty NG Replace
4
OK go to 5

EXTERIOR 51

Check left / right sensor for faulty NG Replace
5
OK go to 6
6 Replace reverse sensor control unit OK Stop
T
AF
R
D

51 EXTERIOR
INSTALLATION STANDARD OPERATION PROCEDURE WCH051SPROC11014
STEP 1: SENSOR DIMENSION AND FITTING
T
AF
R
DOIQC051R11044
Dimension Description
D
1 600 mm (23.62 in) ± 3 mm (0.12 in)

2 300 mm (11.81 in) ± 3 mm (0.12 in)
3 653 mm (25.71 in) ± 3 mm (0.12 in)
Bumper hole Hole 2 x Ø 28 mm (1.1 in)
STEP 2: SENSOR AND CABLE
1. Insert both sensor front cover into bumper
hole (Ø 28 mm (1.1 in) ).
NOTE:
Ensure sensor front cover dot mark is posi-
tioned upwards.
DOIQC051R11046

EXTERIOR 51
2. Fit the sensor eye to the sensor front cover.

NOTE :
• Do not drop the sensor eye.
• Ensure sensor eye lock properly fit at the
front cover hole.
3. Connect the sub-harness link connector to
the sensor eye.
4. Lay both sub-harness link along the rear
bumper and clip it.
5. Connect the sub-harness link connector to
the rear body harness connector.
DOIQC051R11047
STEP 3: CONTROL UNIT AND BUZZER

Install the control unit and buzzer inside lugage
compartment with rigid mounting nut to the
specified torque.
0.5 kgm (5 Nm, 3.62 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
T
ft.lbs)
AF
R
D
DOIQC051R11048

51 EXTERIOR
STEP 4: WIRING AND CONNECTION

1. Follow the routine connection as shown in
the illustration.
1.1 Sensor side:
Symbol Description
1
To ⇒ Right sensor
2
3
To ⇒ Left sensor
4
1.2 Control unit side:
Symbol Description
1 Buzzer (+)
2 Buzzer (-)
3 Earth (-)
Reverse lamp or back-up
4
lamp (+) 12 V
T
AF
DOIQC051R11049
R
D

EXTERIOR 51
REVERSE SENSOR, CONTROL UNIT AND BUZZER / 47
REVERSE SENSOR, CONTROL UNIT AND BUZZER WCH051SASSY11017
T
AF
R
DOIQC051R11050
D

• Rear bumper (Refer to page 51/8 )
• Rear end and rear quarter trim (Refer to GROUP 52A – Trims)
Reverse sensor removal steps
1. Rear bumper assy
2. Reverse sensor assy
Control unit and Buzzer removal steps
3. Reverse sensor control unit
4. Buzzer

51 EXTERIOR
REVERSE WARNING SYSTEM

WCH051SPROC11015
REVERSE SENSOR PERFORMANCE

1. When engaging reverse gear, a “BEEP”
sound will be heard and indicates that the
system is working.
T
AF
DOIQC051R11051
2. The speed of the beeping sound reflects the

distance of the objects from the vehicle and
non-stop beeping sound will indicate a very
R
near object or obstacle.
Symbol Description
D
A Vehicle moving reverse po-

sition
B Vehicle in parking position
ZONE 1 Continuous beep (Non-
stop)
DOIQC051R11052
ZONE 2 8 beep per second

EXTERIOR 51
3. The blind zone is the area where the sensor

cannot detect any obstacle beyond the ultra-
sonic radiation.
Symbol Description
1 Sensor eyes
2 Rear bumper facia
3 Blind zone
DOIQC051R11053
T
AF
R
D

51 EXTERIOR
T
AF
DOIQC051R11054
R
DETECTING RANGE AND TYPE OF SIGNAL

ZONE 1 200-450 mm (7.87-17.72 in) BUZZER — Continuous beep
(Non-stop)
D
ZONE 2 450-700 mm (17.72-27.56 in) BUZZER — 8 beep per second

TESTING METHOD AND PROCEDURE
1. Ensure installation & connection wire is cor-
rect.
2. Ensure connection wire not loose.
3. Switch ignition to “ON” position.
4. Engage gear to reverse (R) position.
5. Take a solid object i.e. PVC pipe Ø 70 mm
(2.76 in). The solid object should approximate
hight 30 cm (11.81 in) or 50 cm (19.68 in) or
70 cm (27.56 in) .
6. Move the solid object from a distance of
1200 mm (47.24 in) to 950 mm (37.4 in) ,
950 mm (37.4 in) to 700 mm (27.56 in) ,
700 mm (27.56 in) to 450 mm (17.72 in) ,
and 450 mm (17.72 in) to 200 mm (7.87 in)
forwards the vehicle in 4 zones. Result of the

EXTERIOR 51
test should similar to the detection zones

pattern.
IMPORTANT
The Reverse Warning System may not operate
accurately and the detection zones may be nar-
rowed under the following situation.
1. Angular reflective objects.
2. Very tiny and thin objects like rope.
3. Conical objects.
4. Objects those readily absorb sound wave.
5. If mud, dirt or other objects cover the sensor.
6. On irregular surface roads, slant street and
driving area with weeds.
7. Very strong frequency interference, industrial
air tools, frequency transceiver, motorcycle,
sharp noise from machine or tools, etc. at
surrounding.
T
AF
R
D

51 EXTERIOR
NOTE
T
AF
R
D

INTERIOR 52A
Content /1
52A INTERIOR
SPECIAL TOOL ......................................................................... 52A/2
TOOL .................................................................................. 52A/2
INSTRUMENT PANEL ................................................................. 52A/2

BOLT AND SCREW .................................................................. 52A/2
INSTRUMENT PANEL ASSEMBLY ................................................... 52A/3

DISCONNECT AND RECONNECT WIRING HARNESS CONNECTOR ......... 52A/3
DISASSEMBLY AND REASSEMBLY ............................................... 52A/7
FLOOR CONSOLE ...................................................................... 52A/11

HEADLINING ........................................................................... 52A/14
T
TRIMS .................................................................................... 52A/18

AF
TRIMS UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A/18
TRIMS LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A/20
TRUNK ROOM TRIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A/23
FRONT SEAT ............................................................................ 52A/28

R

FRONT SEAT RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A/29
REAR SEAT RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A/30
D
LUBRICATION POINT ............................................................... 52A/31
REAR SEAT .............................................................................. 52A/32

TYPE A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A/32
TYPE B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A/33
REAR SEAT ASSY RH (TYPE A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A/34
REAR SEAT ASSY LH (TYPE A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A/35
REAR SEAT ASSY (TYPE B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A/36
REMOVAL SERVICE POINT (TYPE A) ............................................. 52A/37
FRONT SEAT BELT ..................................................................... 52A/41

REAR SEAT BELT ....................................................................... 52A/42


52A INTERIOR
/2 SPECIAL TOOL
SPECIAL TOOL WCH52ASTOOL11001
TOOL
Removal of switch, trim,

etc.
DOIIC52AR9001
INSTRUMENT PANEL WCH52ASPECS11001
BOLT AND SCREW

For installation of the instrument panel, the bolts and screws described below are used.
Name Size mm (DxL) Shape

5 mm (0.2 in) x 12 mm (0.47 in)
Tapping screw
T
5 mm (0.2 in) x 25 mm (0.98 in)
AF
5 mm (0.2 in) x 16 mm (0.63 in)
DOIIC52AR9022
5 mm (0.2 in) x 16 mm (0.63 in)

R
Washer-assembled screw
6 mm (0.24 in) x 12 mm (0.47 in)
DOIIC52AR9024
D
6 mm (0.24 in) x 20 mm (0.79 in)
Washer-assembled bolt
6 mm (0.24 in) x 30 mm (1.18 in)
DOIIC52AR9025
D = Thread diameter
L = Effective thread length

INTERIOR 52A
INSTRUMENT PANEL ASSEMBLY /3
INSTRUMENT PANEL ASSEMBLY WCH52ASASSY11002
DISCONNECT AND RECONNECT WIRING HARNESS CONNECTOR
T
AF
R
D
DOIQC52AR11002

52A INTERIOR
/4 INSTRUMENT PANEL ASSEMBLY
CAUTION : SRS
• Wait at least 5 minutes after disconnecting the battery cable before doing any further work.
• When removing and installing the floor console (Vehicle equipped with SRS), do not let it bump
against the SRS-ECU.
• For the passenger side air bag module removal and installation, always observe the service
procedures (Refer to Group 52B SRS – Air Bag Module and Clock Spring).
T
DOIQC52AR11003
NOTE :
(1) To remove the instrument panel assembly, ensure all instrument panel wiring harness connectors
are disconnected.
AF
(2) Connect all the instrument panel wiring harness connectors properly before installing the instru-
ment panel assembly.
Disconnection steps
1. LED assy harness connector 13. Wiper switch harness connector
2. Front power socket (+) harness connector 14. Clock spring harness connector
3. Front power socket (-) harness connector 15. Key ring antenna harness connector (If-fitted)
R
4. USB harness connector 16. Steering lock switch harness connector (If-fitted)
5. Rear power socket harness connector 17. Ignition switch harness connector (If-fitted)
6. Gear shift harness connector 1 (CVT) 18. Steering angle sensor harness connector (If-fit-
D
7. Gear shift harness connector 2 (CVT) ted)

8. Diagnostic connector 19. Body harness B connector
9. In-car sensor harness connector (If-fitted) 20. Body harness A connector
10. Meter combination harness connector 21. Engine harness 1 connector
11. Head lamp switch harness connector 22. Feeder antenna connection
12. Turn signal switch harness connector 23. HVAC Sub harness connector

INTERIOR 52A
REMOVAL AND INSTALLATION WCH52ASASSY11003
T
AF
R
D
DOIQC52AR11004

52A INTERIOR
CAUTION : SRS
• When removing and installing the floor console (Vehicle equipped with SRS), do not let it bump
• For the passenger side air bag module removal and installation, always observe the service
procedures (Refer to Group 52B SRS – Air Bag Module and Clock Spring).
• Removal and installation Floor Console assembly (Refer to 52A/11 ).
• Removal and installation Gear shift lever (Refer to GROUP 022 (M/T) and GROUP 023 (A/T) –
Transmission control).
• Removal and installation Steering Wheel and Shaft (Refer to GROUP 37A – Steering).
• Removal and installation Cowl side trim RH and LH (Refer to 52A/18 ).
• Disconnect the instrument panel wiring harness connector (Refer to page 52A/3 ).
• Disconnect the antenna cable (Refer to GROUP 054 – Antenna).
NOTE :
(1) To remove the instrument panel assembly, ensure all the instrument panel wiring harness con-
nectors and antenna cable are disconnected.
(2) Connect all the instrument panel wiring harness connectors and antenna cable properly after
installing the instrument panel assembly.
Removal steps
1. Lower trim assy side RH
2. Lower trim assy side LH
3. Cover fuse box assy RH
T
AF
4. Panel assy lower RH
5. Column lower cover
6. Column upper cover
7. Cover meter combi assy
8. Meter combination
9. Glove box assy
R
10. Front pillar assy trim RH

11. Front pillar assy trim LH
12. Instrument panel assy
D

INTERIOR 52A
T
AF
R
D
DOIQC52AR11005

52A INTERIOR
Disassembly steps
1. Instrument panel finisher, passenger side RH 12. Cross beam assy
2. Panel centre assy 13. Instrument panel wiring harness
3. Switch assy centre 14. Passenger Air-bag assembly
4. Switch assy LH 15. Duct, side defroster LH (If-fitted)
5. Switch assy RH 16. Duct, side defroster RH (If-fitted)
6. Head audio unit assy 17. Instrument panel fixing support
7. Passenger Air-bag switch (PAB switch) 18. Duct, centre defroster
8. Switch assy, panel (Without start button switch) 19. Duct, assy front ventilation
9. Switch assy, panel (With start button switch) 20. Solar sensor (If-fitted)
10. Hock assy, grocery 21. Panel, instrument
11. Pad, instrument assy
T
AF
R
D

INTERIOR 52A
LOWER TRIM ASSY SIDE RH/LH REMOVAL

Use the special tool to pry out the lower trim
assy.
DOIQC52AR11011
FRONT PILLAR ASSY TRIM RH/LH REMOVAL

1. Remove the front door weatherstrip.
T
AF
DOIQC52AR11009
2. Use the small screw driver to pry out the

front pillar assy trim cover.
R
D
DOIQC52AR11007
3. Remove the tapping screw.
DOIQC52AR11008

52A INTERIOR
/ 10 INSTRUMENT PANEL ASSEMBLY
4. Remove the front pillar assy trim.
DOIQC52AR11010
COVER METER COMBINATION ASSY

REMOVAL
1. Remove the tapping screw (2 pieces).
T
AF
DOIQC52AR11012
2. Use the special tool to pry out the cover

meter combination assy.
R
D
DOIQC52AR11013

INTERIOR 52A
FLOOR CONSOLE / 11
FLOOR CONSOLE WCH52ASASSY11004
T
AF
R
DOIQC52AR11014
D
CAUTION :
(1) When removing and installing the floor console (Vehicle equipped with SRS) DO NOT let bump
(2) Turn “ON” ignition switch and apply brake pedal before move the selector lever (CVT only)
Floor console assy part:
1. Cover frame shift lever assy 7. Plug cup holder
2. Gear knob (M/T) 8. Instrument panel center cover (RH)
3. Cover assy shift lever (M/T) 9. Instrument panel center cover (LH)
4. Slide cover box assy 10. Floor console (Low-Line)
5. Iphone box assy 11. Floor console (Medium-Line and High line)
6. Cover parking brake front

52A INTERIOR
/ 12 FLOOR CONSOLE
T
AF
R
DOIQC52AR11015
Disassembly steps
1. Console floor 9. Frame power pocket
D
2. Console upper A 10. Plug power point

3. Console upper B 11. Socket assy power point
4. Cover parking brake rear 12. Wire harness main
5. Retainer parking brake 13. Wire harness upper A
6. Lid assy 14. Wire harness upper B
7. Bracket connection console 15. Hand brake service cover
8. Bracket heat stick 16. Nut, speed

INTERIOR 52A
FLOOR CONSOLE / 13
COVER FRAME SHIFT LEVER ASSY REMOVAL

1. Use the special tool to pry out the cover
frame shift lever assy as shown in the figure.
2. Pull out the cover frame shift lever assy from
the instrument panel.
DOIQC52AR11016
T
AF
R
D

52A INTERIOR
/ 14 HEADLINING
HEADLINING WCH52ASASSY11005
T
AF
R
DOIQC52AR11017
D

• Removal and Installation of High mounted stop lamp, Map lamp and Room lamp (Refer to GROUP
054).
• Removal and Installation of front pillar trim, center pillar trim and rear pillar trim (Refer to 52A/18
).
Removal steps
1. Room lamp assy
2. Map lamp assy
3. Sunvisor assy LH
4. Sunvisor assy RH
5. Sunvisor holder
6. Assist grip plug
7. Assist grip front RH
8. Assist grip front LH
9. Assist grip rear RH
10. Assist grip rear LH
11. Clip
12. Headlining

INTERIOR 52A
HEADLINING / 15
NOTE:
(1) Remove the front pillar trim, center pillar
upper trim and rear pillar assy trim before
removing the headlining. (Refer to 52A/18
).
(2) Remove the High mounted stop lamp before
removing the headlining. (Refer to GROUP
054 - High mounted stop lamp).
ROOM LAMP REMOVAL

1. Use a special tool to pry out the room lamp
lens.
DOIQC52AR12014
T
AF
2. Remove the room lamp mounting screws.
R
D
DOIQC52AR12015
3. Disconnect the room lamp connector.
DOIQC52AR12016

52A INTERIOR
/ 16 HEADLINING
MAP LAMP REMOVAL

1. Use a special tool to pry out the map lamp
lens.
DOIQC52AR12010
2. Remove the map lamp mounting screws.
T
AF
DOIQC52AR12011
3. Disconnect the map lamp connector.

R
D
DOIQC52AR12012
CLIP REMOVAL
Remove the all clips by using the special tool.
DOIQC52AR12013

INTERIOR 52A
HEADLINING / 17
HEADLINING REMOVAL
Remove the headlining through the rear door
opened as shown in the illustration.
DOIQC52AR11018
T
AF
R
D

52A INTERIOR
/ 18 TRIMS
TRIMS WCH52ASASSY11006

TRIMS UPPER
T
AF
R
D
DOIQC52AR11019

INTERIOR 52A
TRIMS / 19
Front pillar trim assy removal steps

1. Front pillar trim assy plug
2. Screw washer assy
3. Front pillar trim assy
4. Clip trim
Center pillar upper pillar trim assy removal steps
5. Center pillar upper trim assy plug
7. Center pillar upper trim assy
8. Clip trim
Rear pillar trim assy removal steps
9. Rear pillar trim assy plug
11. Rear pillar trim assy
12. Clip trim
Rear shelf trim assy removal steps
13. Rear shelf trim assy
14. Clip trim
T
AF
R
D

52A INTERIOR
/ 20 TRIMS
TRIMS LOWER
T
AF
R
D
DOIQC52AR11020

INTERIOR 52A
TRIMS / 21
Front trim side sill assy removal steps

1. Screw tapping
2. Front trim side sill assy
3. Clip trim
Rear trim side sill assy removal steps
4. Screw tapping
5. Rear trim side sill assy
6. Clip trim
Trim center pillar lower assy removal steps
7. Trim center pillar lower assy
8. Clip trim
T
AF
R
D

52A INTERIOR
/ 22 TRIMS
T
AF
DOIQC52AR11021
R
Trim scuff plate removal steps

1. Trim scuff plate front
2. Trim scuff plate rear
D

INTERIOR 52A
TRIMS / 23
TRUNK ROOM TRIMS
T
AF
R
D
DOIQC52AR11022

52A INTERIOR
/ 24 TRIMS
Trunk room trim removal steps

1. Clip trim
2. Trunk room trim
Trunk floor board assy removal steps
3. Trunk floor board assy
Rear end trim assy removal steps
1. Clip trim
2. Rear end trim assy
Trunk side trim assy removal steps
1. Clip trim
2. Trunk side trim assy
T
AF
R
D

INTERIOR 52A
TRIMS / 25
FRONT PILLAR ASSY TRIM RH/LH REMOVAL

DOIQC52AR11009

front pillar assy trim cover.
T
AF
DOIQC52AR11007
3. Remove the tapping screw.

R
D
DOIQC52AR11008
4. Remove the front pillar assy trim.
DOIQC52AR11010

52A INTERIOR
/ 26 TRIMS
CENTER PILLAR UPPER TRIM RH/LH

REMOVAL
DOIQC52AR11023
2. Remove the trim center pillar lower assy.
T
AF
DOIQC52AR11025

center pillar upper trim assy plug.
R
D
DOIQC52AR11024
4. Remove the tapping screw and remove the

center pillar upper trim assy.
DOIQC52AR11029

INTERIOR 52A
TRIMS / 27
REAR PILLAR TRIM ASSY RH/LH REMOVAL

1. Remove the rear door weatherstrip.
DOIQC52AR11026
2. Use the small screw driver to pry out the rear

pillar trim assy plug.
T
AF
DOIQC52AR11028
3. Remove the tapping screw and remove the

rear pillar trim assy.
R
D
DOIQC52AR11027

52A INTERIOR
/ 28 FRONT SEAT
FRONT SEAT WCH52ASASSY11007
T
AF
R
DOIQC52AR11030
D

• Disconnect the inner seat belt connector (Vehicles with pre-tensioner).
Removal steps
1. Front anchor cover
2. Rear anchor cover
3. Front seat assembly
T1 : 3.5~5.5 kgm (35~55 Nm, 25.32~39.78 ft.lbs)
T2 : 2.4~3.6 kgm (24~36 Nm, 17.36~26.04 ft.lbs)

INTERIOR 52A
FRONT SEAT / 29

FRONT SEAT RH
T
AF
R
DOIQC52AR11031
D
Disassembly steps
1. Headrest assy 9. Buckle with switch
2. Headrest guide free 10. Inner cover RH
3. Headrest guide lock 11. Front cushion assembly
4. Knob recliner RH 12. Front back assembly
5. Ring snap 13. Trim cover headrest
6. Cap height adjuster RH 14. Trim cover front back RH
7. Knob height adjuster RH 15. Trim cover front cushion RH
8. Outer cover RH
T1 : 1.1~1.3 kgm (11~13 Nm, 7.96~9.4 ft.lbs)
T2 : 3.4~5.4 kgm (34~54 Nm, 24.59~39.06 ft.lbs)
T3 : 4.5~5.5 kgm (45~55 Nm, 32.55~39.78 ft.lbs)

52A INTERIOR
/ 30 FRONT SEAT
REAR SEAT RH
T
AF
R
DOIQC52AR12001
Disassembly steps
1. Headrest assy 9. Inner cover LH
D
2. Headrest guide lock 10. Front back assembly

3. Headrest guide free 11. Front cushion assembly
4. Grocery hook 12. Trim cover headrest
5. Knob recliner lH 13. Trim cover front back LH
6. Ring snap 14. Trim cover front cushion LH
7. Outer cover LH
8. Buckle with switch
T1 : 3.4~5.4 kgm (34~54 Nm, 24.59~39.06 ft.lbs)
T2 : 4.5~5.5 kgm (45~55 Nm, 32.55~39.78 ft.lbs)

INTERIOR 52A
FRONT SEAT / 31
LUBRICATION POINT
T
AF
R
DOIQC52AR12002
Symbol:
D
— Apply Grease (Low temperature multipurpose grease for metals and polymers).

52A INTERIOR
/ 32 REAR SEAT
REAR SEAT WCH52ASASSY12001

TYPE A
T
AF
R
DOIQC52AR12003
D
Removal steps
1. Rear seat cushion assy RH
2. Rear seat cushion assy LH
3. Bush
4. Rear seat side back assy RH
5. Rear seat side back assy LH
6. Rear seat back assy RH
7. Rear seat back assy LH
T1 :2.4~3.6 kgm (24~36 Nm, 17.36~26.04 ft.lbs)
T2 : 3.5~5.5 kgm (35~55 Nm, 25.32~39.78 ft.lbs)

INTERIOR 52A
REAR SEAT / 33
TYPE B
T
AF
R
DOIQC52AR12006
D
Removal steps
• Pulling the rear seat stopper belt (A) forward.
1. Rear seat cushion assy
2. Rear seat side back assy RH
3. Rear seat side back assy LH
4. Rear seat back assy
T1 : 3.5~5.5 kgm (35~55 Nm, 25.32~39.78 ft.lbs)

52A INTERIOR
/ 34 REAR SEAT

REAR SEAT ASSY RH (TYPE A)
T
AF
R
DOIQC52AR12004
D
Disassembly steps
1. Rear seat side back assy RH 9. Center armrest assy
2. Trim cover rear seat side back assy RH 10. Trim cover rear seat back RH
3. Headrest assy 11. Cup holder rear
4. Knob latch (Folding down) 12. Trim cover center armrest
5. Bezel latch (Folding down) 13. Rear seat cushion assy RH
6. Headrest guide lock 14. Connecting rod
7. Headrest guide free 15. Trim cover rear seat cushion RH
8. Rear seat back assy RH
T1 : 1.8~2.4 kgm (18~24 Nm, 13.02~17.36 ft.lbs)
T2 : 0.9~1.1 kgm (9~11 Nm, 6.51~7.96 ft.lbs)

INTERIOR 52A
REAR SEAT / 35
REAR SEAT ASSY LH (TYPE A)
T
AF
R
DOIQC52AR12005
Disassembly steps
1. Rear seat side back assy LH 7. Headrest guide free
D
2. Trim cover rear seat side back assy LH 8. Rear seat back assy LH
3. Headrest assy 9. Trim cover rear seat back LH
4. Knob latch (Folding down) 10. Rear seat cushion assy LH
5. Bezel latch (Folding down) 11. Connecting rod
6. Headrest guide lock 12. Trim cover rear seat cushion LH
T1 : 0.9~1.1 kgm (9~11 Nm, 6.51~7.96 ft.lbs)

52A INTERIOR
/ 36 REAR SEAT
REAR SEAT ASSY (TYPE B)
T
AF
R
DOIQC52AR12007
Disassembly steps
1. Rear seat side back assy RH 6. Trim cover rear seat cushion
D
2. Trim cover rear seat side back assy RH 7. Rear seat back assy
3. Rear seat side back assy LH 8. Trim cover rear seat back
4. Trim cover rear seat side back assy LH 9. Rear seat stopper
5. Rear seat cushion assy

INTERIOR 52A
REAR SEAT / 37
REMOVAL SERVICE POINT (TYPE A)

WCH52ASPROC12001
SEAT CUSHION (RH/LH) REMOVAL

Lift up the seat cushion, release the bush from
the hinge and slide out hinge cushion fold from
the lock (as shown arrow).
DOIQC52AR12024
REAR CUSHION BUSH REMOVAL

Using the plier remove the rear cushion bush.
T
AF
DOIQC52AR12026
REAR SEAT SIDE BACK ASSY (RH/LH)

REMOVAL
R
1. Remove the rear seat side back assy mount-

ing bolt.
D
DOIQC52AR12028
2. Push the lock button to fold down the rear

seat back assy.
DOIQC52AR12027

52A INTERIOR
/ 38 REAR SEAT
3. Push the rear seat side back assy upward, to

release the attachment wire from the hook.
DOIQC52AR12029
SEAT BACK ASSY (RH/LH) REMOVAL

1. Remove the rear seat back assy front
mounting bolts (4 pieces).
T
AF
DOIQC52AR12031

seat back assy (RH).
R
D
DOIQC52AR12027

seat back assy (LH) .
DOIQC52AR12032

INTERIOR 52A
REAR SEAT / 39
4. Remove the rear seat back assy rear mount-

ing nuts (4 pieces).
DOIQC52AR12033
5. Remove the seat back assy LH.
T
AF
DOIQC52AR12034
6. Remove the seat back assy RH.

R
D
DOIQC52AR12035

REAR SEAT SIDE BACK ASSY (RH/LH)
INSTALLATION
1. Push the rear seat side back assy downward,
to hang the attachment wire to the body
side hook.
DOIQC52AR12030

52A INTERIOR
/ 40 REAR SEAT
2. Ensure the attachment wire properly seat

onto the body side hook and tighten the bolt
DOIQC52AR12037
SEAT BACK ASSY (RH/LH) INSTALLATION

the seat back assy.
2. After installed, inspect the rear seat back by
pulling forward to ensure securely latch
locked to the striker.
T
AF
R
D
DOIQC52AR12036
SEAT CUSHION ASSY (RH/LH) INSTALLATION

Slide in hinge cushion fold to the lock (as shown
arrow) and fix the bush to the hinge.
DOIQC52AR12025

INTERIOR 52A
FRONT SEAT BELT / 41
FRONT SEAT BELT WCH52ASASSY12002
T
AF
R
DOIQC52AR12008
D
CAUTION:
For seat belt with pre-tensioner removal and installation procedure, (Refer to Group 52B - Seat Belt
with Pre-tensioner)
Front seat belt assy removal steps Buckle assy removal steps
• Front trim side sill and rear trim side sill removal • Front seat removal (Refer to page 52A/28 )
(Refer to page 52A/18 ) 5. Fron seat assembly
1. Trim center pillar lower assy 6. Buckle assy
2. Seat belt garnish
3. Front seat belt assy
4. Center pillar upper trim assy
NOTE
After provisionally tightening the seat belt assembly mounting bolt in every installation locations,
fully tighten them to the specified torque.
T1 : 3.5~5.5 kgm (35~55 Nm, 25.32~39.78 ft.lbs)

52A INTERIOR
/ 42 REAR SEAT BELT
REAR SEAT BELT WCH52ASASSY12003
T
AF
R
DOIQC52AR12009
D

• Rear seat (Refer to page 52A/32 )
Removal steps
1. Rear shelf trim assy
2. Rear seat belt assy RH
3. Rear centre seat belt assy
4. Rear seat belt assy LH
5. Rear inner seat belt assy
NOTE
After provisionally tightening the seat belt assembly mounting bolt in every installation locations,
T1 : 3.5~5.5 kgm (35~55 Nm, 25.32~39.78 ft.lbs)

SRS 52B
Content /1
52B SRS
GENERAL INFORMATION ............................................................ 52B/4
SRS SERVICE PRECAUTIONS ......................................................... 52B/6

COMPONENT HANDLING AFTER CRASH ....................................... 52B/9
SPECIAL TOOLS ........................................................................ 52B/9
TEST EQUIPMENT ..................................................................... 52B/10
PROTON ADVANCE DIAGNOSTIC TOOL (PADT-II) .............................. 52B/11

SPECIAL FUNCTIONS ................................................................ 52B/11
SRS INSPECTION USING SPECIAL FUNCTION IN PADT-II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/11
TROUBLESHOOTING .................................................................. 52B/12

STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING ................... 52B/12
DIAGNOSIS FUNCTION ............................................................. 52B/12
Diagnosis Codes Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/12
Erasing Diagnosis Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/12
SRS WARNING LAMP INSPECTION ............................................... 52B/12
DYNAMIC DISPLAY REFERENCE TABLE .........................................
FAULT CODE REFERENCE TABLE .................................................
DRIVER SIDE IMPACT SENSOR ...................................................
T 52B/12
52B/13
52B/20
AF
INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/20
PASSENGER SIDE IMPACT SENSOR .............................................. 52B/22
DRIVER AIRBAG ..................................................................... 52B/24
PASSENGER AIRBAG ................................................................ 52B/27
R
DRIVER BELT PRE-TENSIONER .................................................... 52B/30

PASSENGER BELT PRE-TENSIONER ............................................... 52B/33
D
DRIVER FRONT IMPACT SENSOR ................................................ 52B/36

PASSENGER FRONT IMPACT SENSOR ........................................... 52B/38
DRIVER SIDE AIRBAG ............................................................... 52B/40
PASSENGER SIDE AIRBAG ......................................................... 52B/43
PASSENGER CURTAIN AIRBAG (*IF FITTED) .................................... 52B/46
DRIVER CURTAIN AIRBAG (*IF FITTED) ......................................... 52B/49
DRIVER LAP PRE-TENSIONER (*IF FITTED) ...................................... 52B/52
PASSENGER LAP PRE-TENSIONER (*IF FITTED) ................................ 52B/55
PASSENGER AIRBAG DEACTIVATION SWITCH ................................. 52B/58
PASSENGER AIRBAG DEACTIVATION INDICATOR ............................. 52B/61
CAN COMMUNICATION ........................................................... 52B/64

52B SRS
/2 Content
SRS MAINTENANCE ................................................................... 52B/66

SRS WARNING LAMP CHECK ..................................................... 52B/67
SRS COMPONENT VISUAL CHECK ................................................ 52B/67
SRS Control Unit (SRS-ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/68
Air Bag Modules, Steering Wheel and Clock Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/68
INSTRUMENT PANEL WIRING HARNESS/FLOOR WIRING HARNESS ....... 52B/70
POST INSTALLATION INSPECTION ................................................ 52B/70
POST COLLISION DIAGNOSIS ....................................................... 52B/71

SRS – ECU MEMORY CHECK ...................................................... 52B/71
REPAIR PROCEDURE ................................................................ 52B/71
When Air bag Deploy or Seat Belt Pre-Tensioner Operates in a Collision . . . . . . . . . . . . . 52B/71
When Side and Curtain Airbags are Operates in a Collision . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/71
When Seat Belt Pre-Tensioner Operates in a Collision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/71
When Air Bag or Seat Belt Pre-Tensioner Does Not Deploy in Low Speed Collision . . . 52B/72
INDIVIDUAL COMPONENT SERVICE ............................................... 52B/73
WARNING / CAUTION LABEL ....................................................... 52B/73
SRS AIR BAG CONTROL UNIT (SRS-ECU) .......................................... 52B/76

REMOVAL AND INSTALLATION ................................................... 52B/76
INSPECTION
T
..........................................................................
52B/78
52B/78
52B/79
AF
POST INSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/80
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/80
AIR BAG MODULE AND CLOCK SPRING .......................................... 52B/81

REMOVAL AND INSTALLATION .................................................. 52B/81
INSPECTION .......................................................................... 52B/84
R
CLOCK SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/84

INSTALLATION SERVICE POINT .................................................. 52B/85
INSPECTION .......................................................................... 52B/85
AIR BAG MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/85
D
CLOCK SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/86

CLOCK SPRING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/86
INSTALLATION SERVICE POINTS .................................................. 52B/87
INSPECTION ......................................................................... 52B/89
DRIVER AIR BAG MODULE / FRONT PASSENGER AIR BAG MODULEif so equipped 52B/89
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT PASSENGER AIR BAG MODULE ........................................... 52B/90

INSPECTION ......................................................................... 52B/95
FRONT PASSENGER'S AIR BAG MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/95
CURTAIN AIR BAG MODULE ........................................................ 52B/96

REMOVAL SERVICE POINTS ....................................................... 52B/98
FRONT IMPACT SENSOR CONNECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/98
POST-REMOVAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/98
PRE-INSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/98
INSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/98
POST-INSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/99

SRS 52B
Content /3
SEAT BELT WITH PRE-TENSIONER .................................................. 52B/100

SEAT BELT WITH PRETENSIONER ................................................... 52B/102

INSPECTION .......................................................................... 52B/102
SEAT BELT WITH PRE-TENSIONER CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/102
SIDE AIRBAG MODULE ............................................................... 52B/103

PRE-REMOVAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/105
FRONT IMPACT SENSOR ............................................................. 52B/106

FRONT IMPACT SENSOR CONNECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/107
T
POST-INSTALLATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIDE IMPACT SENSOR ................................................................ 52B/109

52B/108
AF
SIDE IMPACT SENSOR CONNECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/111
PASSENGER AIR BAG DEACTIVATION SWITCH .................................. 52B/113

R

SIDE IMPACT SENSOR CONNECTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/114
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/114
D
UN-DEPLOYED AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOS- 52B/114
A L ........................................................................................
DEPLOYMENT INSIDE THE VEHICLE ............................................. 52B/115
Driver's air bag module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/115
Seat belt pre-tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/117
DEPLOYMENT OUTSIDE THE VEHICLE .......................................... 52B/118
Driver's side air bag module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/119
Seat belt pre-tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52B/120
AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCED- 52B/122
U R E ......................................................................................
GENERAL INFORMATION .......................................................... 52B/122
DEPLOYED AIR BAG MODULE OR OPERATED SEAT BELT PRE-TENSIONER 52B/123

DISPOSAL PROCEDURES .............................................................

52B SRS
GENERAL INFORMATION WCH52BGINFO11003
CAUTION
• Carefully read and observe the information in SERVICE PRE CAUTIONS (refer page 52B/6 ) prior
to any service.
• For information concerning troubleshooting or maintenance, always observe the procedures in
the TROUBLESHOOTING (refer page 52B/12 ) 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.
The SRS (Supplemental Restraint System) air bag is a system that is effective with the seat belt fastened,
and it is designed as a supplemental system of the seat belt. The air bag inflates upon a frontal collision
or a side collision to protect the passengers.
The SRS consists of air bag modules, SRS air bag control unit (SRS-ECU), two front impact sensors, two
side impact sensors, SRS warning lamp, clock spring, seat belt pre-tensioner and lap belt pre-tensioner.
Front air bags are located in the centre of the steering wheel and above the glove box. Knee air bag
is installed under the column cover. Side-airbags are located inside the front seatback assemblies. The
curtain air bag module is installed in the roof side sections (from the driver’s and the passenger’s front
pillars to the rear pillars). Each air bag is made up of a folded air bag and an inflator unit. The SRS-
T
ECU under the front floor console monitors the system and has a front air bag safing G-sensor, front
air bag analogue G-sensor and a side (curtain) air bag analogue G-sensor. The front impact sensor is
installed on the headlamp support panel upper in the engine room and contains an analogue G-sensor
AF
and a microcomputer. The side impact sensor is installed in the lower parts of the centre pillars and
contains an analogue G-sensor and a microcomputer. The warning lamp on the instrument panel in-
dicates the operational status of the SRS. The clock spring is installed in the steering column. The seat
belt pre-tensioner and lap belt pre-tensioner is built into the driver’s and passenger’s front seat belt
retractor.
Only authorized service personnel should do work on or around the SRS components. Those service
personnel should read this manual carefully before starting any such work.
R
D

SRS 52B
T
AF
R
D
DOIQC52BR12072
* If fitted

52B SRS
/6 SRS SERVICE PRECAUTIONS
SRS SERVICE PRECAUTIONS WCH52BGINFO11004
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/10 — 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).
• Front seat assembly incorporating side-airbag module (if so equipped).
• Curtain airbag module (if so equipped).
• Side impact sensor (if so equipped).
• Seat belt with pre-tensioner and lap belt with pretensioner (if so equipped).
• Front impact sensor.
• Side impact sensor (if so equipped).
NOTE
If any of these components are diagnosed as faulty, they should only be replaced in accordance
with the INDIVIDUAL COMPONENTS SERVICE procedures in this manual, starting at page
(52B/73 )
T
4. Never attempt to repair the wiring harness connectors of the SRS. If a defective wiring harness is
found, repair or replace it by referring to the table follows.
AF
R
D
DOIQC52BR12030
5. 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
6. 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

SRS 52B
SRS SERVICE PRECAUTIONS /7
DOIQC52BR12003
7. SRS-ECU PIN ASSIGNMENT CORRECTIVE ACTION

1 Battery supply Repair or replace wiring harness
2 - -
3 - -
4 Side Airbag Front Pasenger (+) Repair or replace wiring harness
5
6
7
Side Airbag Front Driver (+)
Side Airbag Front Driver (-)
T
Side Airbag Front Pasenger (-)
Repair or replace wiring harness
AF
8 Front Airbag Passenger (+) Repair or replace wiring harness
9 Front Airbag Passenger (-)
10 Front Airbag Driver (+) Replace clock spring / Repair or re-
11 Front Airbag Driver (-) place wiring harness
12 Curtain Airbag Passenger (+)* Repair or replace wiring harness
R
13 Curtain Airbag Passenger (-)*

14 Curtain Airbag Driver (+)* Repair or replace wiring harness
15 Curtain Airbag Driver (-)*
D
16 Pre-tensioner Passenger (-) Repair or replace wiring harness

17 Pre-tensioner Passenger (+)
18 Pre-tensioner Diver (-) Repair or replace wiring harness
19 Pre-tensioner Diver (+)
20 Lap Pre-tensioner Passenger (-)* Repair or replace wiring harness
21 Lap Pre-tensioner Passenger (+)*
22 Lap Pre-tensioner Diver (-)* Repair or replace wiring harness
23 Lap Pre-tensioner Diver (+)*
24 Front Impact Sensor Driver (-) Repair or replace wiring harness
25 Front Impact Sensor Driver (+)
26 - -
27 - -
28 - -
29 Passenger Airbag On/Off Switch L1 Repair or replace wiring harness
30 - -
31 - -

52B SRS
/8 SRS SERVICE PRECAUTIONS
SRS-ECU PIN ASSIGNMENT CORRECTIVE ACTION

32 Passenger Airbag On/Off Switch L2 Repair or replace wiring harness
33 - -
34 Front Impact Sensor Passenger (-) Repair or replace wiring harness
35 Front Impact Sensor Passenger (+)
36 GND (SW signals) Repair or replace wiring harness
37 - -
38 - -
39 - -
40 - -
41 Side Impact Sensor Passenger (+) Repair or replace wiring harness
42 Side Impact Sensor Passenger (-)
43 Side Impact Sensor Driver (+) Repair or replace wiring harness
44 Side Impact Sensor Driver (-
45 Passenger Airbag Off Lamp Repair or replace wiring harness
46 GND (Battery) Repair or replace wiring harness
47
48
49
-
-
CAN HI
T -
-
Repair or replace wiring harness
AF
50 CAN LO
R
D
DOIQC52BR12004
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
8. SRS components and seat belt, with pre-tensioner should not be subjected to heat, so remove the
SRS-ECU, airbag module (driver's side and front passenger's side if equipped), clock spring, side
impact (if equipped), front seat assemblies (side airbag moduleif equipped), and seat belts with
pre-tensioner before drying or baking the vehicle after painting.
• SRS-ECU, airbag module, clock spring, side impact (if equipped) : 93°C or more
• Seat belt with pre-tensioner: 90°C or more

SRS 52B
SPECIAL TOOLS /9
9. Whenever you finish servicing the SRS, check warning lamp operation to make sure the system
functions properly (Refer to page 52B/12 ).
10. Ensure the Ignition Switch is OFF when PADT-II is connected or disconnected.
11. 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.
COMPONENT HANDLING AFTER CRASH
While the crach happened with airbag or belt pre-tensioner deployed or triggered, Airbag Control
Unit must be replaced as well as other impacted componens. After the Airbag Control Unit firing, it
will be locked permanently and cannot be reuse anymore. Related DTC will also be triggered accord-
ingly.
Reuse of components if no obvious damage;
COMPONENTS REUSE
AIRBAG CONTROL UNIT(ACU) ACU cannot be reused if any of the airbag or belt pre-tensioner is
deployed.
FRONT IMPACT SENSOR (DRIVER • Cannot be reuse after front crash occurred. Replace both Driver
& PASSENGER SIDE) and passenger side component.
T
• If non frontal crash, the component can be reuse if no obvious
damage
AF
SIDE IMPACT SENSOR • Cannot be reuse after side crash occurred. For impacted side must
replace the respective component. For non impacted side, replace
the respective component if obvious damage.
• If non side crash, the components can be reuse if no obvious
damage
SPECIAL TOOLS
R
WCH52BSTOOL11002
Tool Part Number Name Use

570465600 Air bag simulat- • To simulate the air
D
(6pcs) and or and sub har- bag module func-

570763200 ness tion during
(3 pcs) troubleshooting
for safety purpose
DOIKC52BR03134
MB990803 Steering wheel • To remove steer-

puller ing wheel
DOIIC52BR9003

52B SRS
/ 10 TEST EQUIPMENT
TEST EQUIPMENT WCH52BEQUIP11002
interface (VCI)
DOIMC35BR11039

CD
DOIMC35BR11042
T
DLC cable (16-pin OBD
connector; 1 m)
Main diagnosis cable to
VCI
AF
DOIMC35BR11041

USB cable (1.8 m)
PC and VCI
R
DOIMC35BR11046
D

DOIMC35BR11045

Ethernet cable
ing to VCI
DOIMC35BR11040

SRS 52B
PROTON ADVANCE DIAGNOSTIC TOOL (PADT-II) / 11

Cable keeper
cable messy
DOIMC35BR11043

DOIMC35BR11044
DOIMC35BR11047
T
AF
PROTON ADVANCE DIAGNOSTIC
TOOL (PADT-II) WCH52BSPROC11006
SPECIAL FUNCTIONS
SRS INSPECTION USING SPECIAL FUNCTION IN
R
PADT-II
• Connect PADT-II to diagnostic connector
D

• Switch the ignition key to “ON” position.
• Select the vehicle model to be diagnosed in
DOIMC52BR11004 PADT-II menu.
• Select “ACU-AP2”.
• Click on the ECU ID icon (A) to confirm the
on SRS part number.
• The “Data List” button will display the SRS
components' dynamic values.
DOIMC52BR11003

52B SRS
TROUBLESHOOTING WCH52BTSHOT11011
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

Refer to GROUP 002 – HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
DIAGNOSIS FUNCTION
Diagnosis Codes Check
Connect the PADT to the diagnosis connector (16–pins) under the instrument under cover, then check
diagnosis codes (Refer to GROUP 002, basic publication —HOW TO USE TROUBLESHOOTING/INSPECTION
SERVICE POINTS).
Erasing Diagnosis Code
Connect the PADT to the diagnosis connector and erase the diagnosis code.
CAUTION
Turn off the ignition switch before connecting or disconnecting the PADT.
SRS WARNING LAMP INSPECTION
T
AF
R
DOIQC52BR12005
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.
D
3. If the above is not the cause, inspect the diagnosis code.

DYNAMIC DISPLAY REFERENCE TABLE
No. Dynamic Display Units REMARKS
1 Driver Airbag Impedance 2.01 - 4.24 Ω Firing is ensured.
2 Passenger Airbag Impedance 1.77-3.49 Ω Firing is ensured.
3 Driver Belt Pretensioner Impedance 1.77-3.49 Ω Firing is ensured.
4 Passenger Belt Pretensioner Impedance 1.77-3.49 Ω Firing is ensured.
5 Driver Side Airbag Impedance 1.77-3.49 Ω Firing is ensured.
6 Passenger Side Airbag Impedance 1.77-3.49 Ω Firing is ensured.
7 Curtain Airbag Driver Impedance 1.77-3.49 Ω Firing is ensured.
8 Curtain Airbag Passenger Impedance 1.77-3.49 Ω Firing is ensured.
9 Driver Lap Tensioner Impedance 1.77-3.49 Ω Firing is ensured.
10 Front Passenger Lap Tensioner Impedance 1.77-3.49 Ω Firing is ensured.

SRS 52B
No. Dynamic Display Units REMARKS

11 Passenger Airbag Deactivation Switch When Deactivation switch
Impedance ON: 100 Ohm Depending PADS
When Deactivation switch ON/OFF status
OFF: 400 Ohm
12 Passenger Airbag Firing Status When Deactivation Switch
ON: Deactivated by PADS Depending PADS
When Deactivation OFF: ON/OFF status
Active
13 Crash Counter If >0, check the DTC
0
status (max 3)
14 Crash Mode Status Check the DTC status
Before Crash Mode/
when After Crash
After Crash Mode
mode is displayed.
15 Warning Lamp (Current DTC)
OFF/ON Check DTC when;
Status Warning Lamp (History DTC)
OFF/ON 1. Warning lamp (Cur-
Status Warning Lamp (Crash)
OFF/ON rent DTC) is ON
Status Warning Lamp (Diagnostic Session)
OFF/ON 2. Status Warning
Status Warning Lamp (Disabled Al-
T
OFF/ON Lamp (Crash) is ON
gorithm) Status
FAULT CODE REFERENCE TABLE
AF
Fault Code Code name Diagnosed Item Reference Page
B1000-49 Internal fault AIRBAG CU Internal electrical failure Do not attempt to
troubleshoot error.
Replace the air bag
control unit (refer
to 52B/76 )
R
B1001-55 Configuration fault ACU wrong configured or device is not Incorrect ACU unit
configured but physically present installed to vehicle.
Check the correct
D
part number and

the model variant
with supplier.
B1002-4A Driver Impact Sensor 1. timeout during initialization Refer to On vehicle
(PAS) Initialization or 2. status data incomplete service section to
Type incorrect 3. wrong sensor type (incl. protocol or check the sensor
manufacturer) condition.
4. wrong subtype (e.g. sensitivity, axis, Or,
bus-node) Incorrect impact
5. project specific check failed sensor installed to
(e.g.serial ID) vehicle. Check the
6. sensor specific check failed correct part num-
B1002-64 Driver Impact Sensor Sensor data values are >x LSB or <-x ber and the model
(PAS) Plausibility fault LSB for more than y msec variant with suppli-
er.
B1002-96 Driver Impact Sensor Sensor sends "Sensor defect" message
(PAS) Defect
B1002-86 Driver Impact Sensor Sensor transmits parity or CRC error,
(PAS) Communication Manchester error, buffer empty or
other invalid data.

52B SRS

B1003-4A Passenger Impact Sensor 1. timeout during initialization Refer to On vehicle
(PAS) Initialization or 2. status data incomplete service section to
5. project specific check failed (e.g. sensor installed to
serial ID) vehicle. Check the
B1003-64 Passenger Impact Sensor Sensor data values are >x LSB or <-x ber and the model
(PAS) Plausibility LSB for more than y msec variant with suppli-
er.
B1003-86 Passenger Impact Sensor Sensor transmits parity or CRC error,
(PAS) Communication Manchester error, buffer empty or
other invalid data.
B1003-96 Passenger Impact Sensor Sensor sends "Sensor defect" message
(PAS) Defect
B1006-4A Up Front Sensor (UFS) 1. timeout during initialization Refer to On vehicle
Driver Initialization or 2. status data incomplete service section to
Type incorrect
T
3. wrong sensor type (incl. protocol or
manufacturer)
4. wrong subtype (e.g. sensitivity, axis,
check the sensor
condition.
Or,
AF
B1006-64 Up Front Sensor (UFS) Sensor data values are >x LSB or <-x ber and the model
Driver Plausibility LSB for more than y msec variant with suppli-
R
er.
B1006-96 Up Front Sensor (UFS) Sensor sends "Sensor defect" message
Driver Defect
B1006-86 Up Front Sensor (UFS) Sensor transmits parity or CRC error,
D
Driver Communication Manchester error, buffer empty or

other invalid data.
B1007-4A Up Front Sensor (UFS) 1. timeout during initialization Refer to On vehicle
Passenger Initialization or 2. status data incomplete service section to
B1007-64 Up Front Sensor (UFS) Sensor data values are >x LSB or <-x ber and the model
Passenger Plausibility LSB for more than y msec variant with suppli-
er.
B1007-96 Up Front Sensor (UFS) Sensor sends "Sensor defect" message
Passenger Defect
B1007-86 Up Front Sensor (UFS) Sensor transmits parity or CRC error,
Passenger External Com- Manchester error, buffer empty or
munication other invalid data.

SRS 52B

B1008-95 Driver Impact Sensor Short circuit wiring fault with other page52B/20
(PAS) Cross Coupling
B1008-11 Driver Impact Sensor Sensor short to ground
(PAS) Short to Ground
B1008-12 Driver Impact Sensor Sensor short to battery
(PAS) Short to Battery
B1009-95 Passenger Impact Sensor Short circuit wiring fault with other page52B/22
(PAS) Cross Coupling
B1009-11 Passenger Impact Sensor Sensor short to ground
(PAS) Short to Ground
B1009-12 Passenger Impact Sensor Sensor short to battery
(PAS) Short to Battery
B100A-95 Up Front Sensor (UFS) Short circuit wiring fault with other page 52B/36
Driver Cross Coupling sensors
B100A-11 Up Front Sensor (UFS) Sensor short to ground
Driver Short to Ground
B100A-12 Up Front Sensor (UFS) Sensor short to battery
B100B-95
Driver Short to Battery
Up Front Sensor (UFS)
Passenger CrossCoupling
T
Short circuit wiring fault with other page 52B/38
AF
B100B-12 Up Front Sensor (UFS) Sensor short to ground
Passenger Short to Bat-
tery
B100B-11 Up Front Sensor (UFS) Sensor short to battery
Passenger Short to
Ground
R
B1010-95 Driver Airbag Cross Squib is tested for short circuit wiring page52B/24
Coupled fault with other squibs.
B1010-11 Driver Airbag Terminal Squib high side or low side terminal is
D
Short to Ground shorted to ground.

B1010-12 Driver Airbag Terminal Squib high side or low side terminal is
Short to Battery shorted to battery.
B1010-1B Driver Airbag Resistance Squib is open
Open
B1010-1A Driver Airbag Resistance Squib is shorted
Short
B1011-95 Passenger Airbag Squib is tested for short circuit wiring page52B/27
CrossCoupled fault with other squibs.
B1011-11 Passenger Airbag Termin- Squib high side or low side terminal is
al Short to Ground shorted to ground.
B1011-12 Passenger Airbag Termin- Squib high side or low side terminal is
al Short to Battery shorted to battery.
B1011-1B Passenger Airbag Resist- Squib is open
ance Open
B1011-1A Passenger Airbag Resist- Squib is shorted
ance Short

52B SRS

B1012-95 Driver belt pre-tensioner Squib is tested for short circuit wiring page52B/30
B1012-11 Driver belt pre-tensioner Squib high side or low side terminal is
Terminal Short to shorted to ground.
Ground
B1012-12 Driver belt pre-tensioner Squib high side or low side terminal is
Terminal Short to Battery shorted to battery.
B1012-1B Driver belt pre-tensioner Squib is open
Resistance Open
B1012-1A Driver belt pre-tensioner Squib is shorted
Resistance Short
B1013-11 Passenger belt pre-ten- Squib is tested for short circuit wiring page52B/33
sioner Terminal Short to fault with other squibs.
Ground
B1013-95 Passenger belt pre-ten- Squib high side or low side terminal is
sioner CrossCoupled shorted to ground.
B1013-12 Passenger belt pre-ten- Squib high side or low side terminal is
B1013-1B
sioner Terminal Short to
Battery
Passenger belt pre-ten-
T
shorted to battery.
Squib is open
AF
sioner Resistance Open
B1013-1A Passenger belt pre-ten- Squib is shorted
sioner Resistance Short
B1014-95 Driver Side Airbag Squib is tested for short circuit wiring page52B/40
B1014-11 Driver Side Airbag Termin- Squib high side or low side terminal is
R
al Short to Ground shorted to ground.

B1014-12 Driver Side Airbag Termin- Squib high side or low side terminal is
al Short to Battery shorted to battery.
D
B1014-1B Driver Side Airbag Resist- Squib is open

ance Open
B1014-1A Driver Side Airbag Resist- Squib is shorted
ance Short
B1015-95 Passenger Side Airbag Squib is tested for short circuit wiring page52B/43
B1015-11 Passenger Side Airbag Squib high side or low side terminal is
Ground
B1015-12 Passenger Side Airbag Squib high side or low side terminal is
B1015-1B Passenger Side Airbag Squib is open
Resistance Open
B1015-1A Passenger Side Airbag Squib is shorted
Resistance Short

SRS 52B

B1016-95 Passenger Curtain Airbag Squib is tested for short circuit wiring page52B/46
B1016-11 Passenger Curtain Airbag Squib high side or low side terminal is
Ground
B1016-12 Passenger Curtain Airbag Squib high side or low side terminal is
B1016-1B Passenger Curtain Airbag Squib is open
Resistance Open
B1016-1A Passenger Curtain Airbag Squib is shorted
Resistance Short
B1017-95 Driver Curtain Airbag Squib is tested for short circuit wiring page52B/49
B1017-11 Driver Curtain Airbag Squib high side or low side terminal is
Ground
B1017-12 Driver Curtain Airbag Squib high side or low side terminal is
B1017-1B
Terminal Short to Battery
Driver Curtain Airbag
Resistance Open
T
shorted to battery.
Squib is open
AF
B1017-1A Driver Curtain Airbag Squib is shorted
Resistance Short
B1018-95 Driver Lap Pre-tensioner Squib is tested for short circuit wiring page52B/52
Cross Coupled fault with other squibs.
B1018-11 Driver Lap Pre-tensioner Squib high side or low side terminal is
R
Ground
B1018-12 Driver Lap Pre-tensioner Squib high side or low side terminal is
D
B1018-1B Driver Lap Pre-tensioner Squib is open

Resistance Open
B1018-1A Driver Lap Pre-tensioner Squib is shorted
Resistance Short
B1019-95 Passenger Lap Pre-tension- Squib is tested for short circuit wiring page52B/55
er Cross Coupled fault with other squibs.
B1019-11 Passenger Lap Pre-tension- Squib high side or low side terminal is
er Terminal Short to shorted to ground.
Ground
B1019-12 Passenger Lap Pre-tension- Squib high side or low side terminal is
er Terminal Short to Bat- shorted to battery.
tery
B1019-1B Passenger Lap Pre-tension- Squib is open
er Resistance Open
B1019-1A Passenger Lap Pre-tension- Squib is shorted
er Resistance Short

52B SRS

B1022-95 Passenger Airbag Deactiv- PADS is tested for short circuit wiring page52B/58
ation Switch (PADS) Cross fault with other switches.
Coupled
B1022-12 Passenger Airbag Deactiv- PADS is short to battery
ation Switch (PADS) Short
to Battery
B1022-1B Passenger Airbag Deactiv- PADS is open
ation Switch (PADS) Open
Line
B1022-1A Passenger Airbag Deactiv- PADS is short to ground
ation Switch (PADS) Short
Line
B1022-1F Passenger Airbag Deactiv- PADS resistance out of range
ation Switch (PADS) Un-
defined
B1031-14 Passenger Airbag Deactiv- PADI short to ground or open page52B/61
ation Indicator (PADI)
Short to Ground Or Open
B1031-12 Passenger Airbag Deactiv-
ation Indicator (PADI)
T
PADI short to battery
AF
Short to Battery
B1040-17 Battery Too High Battery voltage too high Check the battery
B1040-16 Battery Too Low Battery voltage too low voltage and spe-
cification.
Refer to Group 054
Battery.
R
B1050-00 Front & Belt Pre-tensioner Front BT deployment happens Do not attempt to
Deployment troubleshoot error.
Replace the air bag
control unit, front
D
airbag module and

front belt pre-ten-
sioner (refer to
52B/76 , 52B/81 ,
52B/90 and 52B/100
)
B1051-00 Side Deployment Side airbag deployment happens Do not attempt to
troubleshoot error.
Replace the air bag
control unit, side
air bag component
and front belt pre-
tensioner (refer to
52B/76 , 52B/103
and 52B/100 )
B1052-00 Crash Counter Reached Maximum deployment counter Do not attempt to
Max reached, AIRBAG ECU is no longer re- troubleshoot error.
usable. Replace the air bag
control unit (refer
to 52B/76 )

SRS 52B

U1000-00 CAN Bus OFF 1. Short circuit between CAN_H and page52B/64
CAN_L
2. Short circuit between CAN_H and
battery
3. Heavy bus disturbance
U1003-00 Fault of SRS - ECU Com- AIRBAG ECU message transmission
munication confirmation timeout
U1002-00 Fault of ICM Communica- IP message reception timeout, no
tion message from IP node,
1.CAN network error
2.IP node absence
3. Heavy bus load
U1001-00 Fault of ABS - ECU Com- ABS message reception timeout
munication 1.CAN network error
2.ABS node absence
3. Heavy bus load
U1004-00 Vehicle Speed Info Invalid Vehicle speed information is invalid
U1005-00 Airbag Warning Lamp Airbag lamp mismatch timeout
Fault
T
Warning lamp status is mismatch
AF
R
D

52B SRS
DRIVER SIDE IMPACT SENSOR WCH52BTSHOT11012
T
AF
R
DOIQC52BR12009
INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE

Code No. B1008–95, B1008–11 & B1008–12 Driver Side
D
Probable cause
Impact Sensor
These diagnosis codes are output if there is abnormal • Malfunction of wiring harnesses or con-
resistance between the input terminals of the driver side nectors.
impact sensor • Cross coupling between the (+) and (-)
The trouble causes for each diagnosis code number are of impact sensor
as follows: • Malfunction of SRS-ECU
Fault
PADT-II Display Trouble Causes
Code
B1008-95 Driver Impact Sensor (PAS) Cross Coupling Short circuit wiring fault with other
B1008-11 Driver Impact Sensor (PAS) Short to Ground Sensor short to ground
B1008-12 Driver Impact Sensor (PAS) Short to Battery Sensor short to battery

SRS 52B
CAUTION
Disconnect the negative (-) battery terminal and wait for 60 seconds or more before starting work.
Insulate the disconnected (-) terminal by wrapping the tape (Refer to the item 4 of Service Precautions)
T
AF
R
D
DOIQC52BR12045

52B SRS
PASSENGER SIDE IMPACT SENSOR WCH52BTSHOT11013
T
AF
R
DOIQC52BR12008

Code No. B1009-95, B1009-11 & B1009-12 Passenger Side
D
Probable cause
Impact Sensor
resistance between the input terminals of the passenger nectors.
side impact sensor • Cross coupling between the (+) and (-)
Fault
Code
B1009-95 Passenger Impact Sensor (PAS) Cross Coup- Short circuit wiring fault with other
ling
B1009-11 Passenger Impact Sensor (PAS) Short to Sensor short to ground
Ground
B1009-12 Passenger Impact Sensor (PAS) Short to Bat- Sensor short to battery
tery

SRS 52B
CAUTION
T
AF
R
D
DOIQC52BR12046

52B SRS
DRIVER AIRBAG WCH52BTSHOT11014
T
AF
R
DOIQC52BR12021

Code No. B1010-95, B1010-11, B1010-12, B1010-1B &
D
Probable cause
B1010-1A Driver Airbag
• • Malfunction of clock spring.
These diagnosis codes are output if there is abnormal • Partial disconnection due to incorrect
resistance between the input terminals of the driver clock spring neutral position.
airbag (squib). • Malfunction of wiring harnesses or
connectors.
The trouble causes for each diagnosis code number are • Malfunction of front airbag – driver's
as follows: side module (squib).
• Malfunction of SRS-ECU
Fault
Code
B1010-95 Driver Airbag Cross Coupled Squib is tested for short circuit wiring fault
with other squibs.
B1010-11 Driver Airbag Terminal Short to Ground Squib high side or low side terminal is shor-
ted to ground.
B1010-12 Driver Airbag Terminal Short to Battery Squib high side or low side terminal is shor-
ted to battery.
B1010-1B Driver Airbag Resistance Open Squib is open

SRS 52B
Fault
Code
B1010-1A Driver Airbag Resistance Short Squib is shorted
Data
PADT-II Display Standard value Remarks
List
1 Driver Airbag Impedance Replace the driver airbag if the
2.01-4.24 Ω
value is out range
T
AF
R
D

52B SRS
CAUTION
T
AF
R
D
DOIQC52BR12049

SRS 52B
PASSENGER AIRBAG WCH52BTSHOT11015
T
AF
R
DOIQC52BR12022

Code No. B1011-95, B1011-11, B1011-12, B1011-1B &
D
Probable cause
B1011-1A Passenger Airbag
These diagnosis codes are output if there is abnormal • • Malfunction of wiring harnesses or
resistance between the input terminals of the passenger connectors.
airbag (squib). • Malfunction of passenger airbag –
The trouble causes for each diagnosis code number are passenger airbag module (squib).
Fault
Code
B1011-95 Passenger Airbag CrossCoupled Squib is tested for short circuit wiring fault
with other squibs.
B1011-11 Passenger Airbag Terminal Short to Ground Squib high side or low side terminal is shor-
ted to ground.
B1011-12 Passenger Airbag Terminal Short to Battery Squib high side or low side terminal is shor-
ted to battery.
B1011-1B Passenger Airbag Resistance Open Squib is open
B1011-1A Passenger Airbag Resistance Short Squib is shorted

52B SRS
Data
List
1 Passenger Airbag Impedance Replace the passenger airbag if
1.77-3.49 Ω
the value is out range
T
AF
R
D

SRS 52B
CAUTION
T
AF
R
D
DOIQC52BR12050

52B SRS
DRIVER BELT PRE-TENSIONER WCH52BTSHOT11016
T
AF
R
DOIQC52BR12012

Code No. B1012-95, B1012-11, B1012-12, B1012-1B &
D
Probable cause
B1012-1A Driver Belt Pretensioner
These diagnosis codes are output if there is abnormal
resistance between the input terminals of the driver belt • • Malfunction of wiring harnesses or
pretensioner. connectors.
• Malfunction of driver belt pretensioner
The trouble causes for each diagnosis code number are • Malfunction of SRS-ECU
as follows:
Fault
Code
B1012-95 Driver belt pre-tensioner CrossCoupled Squib is tested for short circuit wiring fault
with other squibs.
B1012-11 Driver belt pre-tensioner Terminal Short to Squib high side or low side terminal is shor-
Ground ted to ground.
B1012-12 Driver belt pre-tensioner Terminal Short to Squib high side or low side terminal is shor-
Battery ted to battery.
B1012-1B Driver belt pre-tensioner Resistance Open Squib is open
B1012-1A Driver belt pre-tensioner Resistance Short Squib is shorted

SRS 52B
Data
List
1 Driver Pre-tensioner Impedance Replace the passenger airbag if
1.77-3.49 Ω
the value is out range
T
AF
R
D

52B SRS
CAUTION
T
AF
R
D
DOIQC52BR12051

SRS 52B
PASSENGER BELT PRE-TENSIONER WCH52BTSHOT11017
T
AF
R
DOIQC52BR12011

Code No. B1013-11, B1013-95, B1013-12, B1013-1B &
D
Probable cause
B1013-1A Passenger Belt Pretensioner
These diagnosis codes are output if there is abnormal • • Malfunction of wiring harnesses or
resistance between the input terminals of the passenger connectors.
belt pretensioner. • Malfunction of passenger belt preten-
The trouble causes for each diagnosis code number are sioner
Fault
Code
B1013-11 Passenger belt pre-tensioner Terminal Short Squib is tested for short circuit wiring fault
to Ground with other squibs.
B1013-95 Passenger belt pre-tensioner CrossCoupled Squib high side or low side terminal is shor-
ted to ground.
B1013-12 Passenger belt pre-tensioner Terminal Short Squib high side or low side terminal is shor-
to Battery ted to battery.
B1013-1B Passenger belt pre-tensioner Resistance Squib is open
Open

52B SRS
Fault
Code
B1013-1A Passenger belt pre-tensioner Resistance Squib is shorted
Short
Data
List
1 Passenger Pre-tensioner Imped- Replace the if the value is out
1.77-3.49 Ω
ance range
T
AF
R
D

SRS 52B
CAUTION
T
AF
R
D
DOIQC52BR12052

52B SRS
DRIVER FRONT IMPACT SENSOR WCH52BTSHOT11018
T
AF
R
DOIQC52BR12006

Code No. B100A-95, B100A-11 & B100A-12 Driver Front
D
Probable cause
Impact Sensor
resistance between the input terminals of the driver nectors.
front impact sensor • Cross coupling between the (+) and (-)
Fault
Code
B100A-95 Up Front Sensor (UFS) Driver Cross Coupling Short circuit wiring fault with other sensors
B100A-11 Up Front Sensor (UFS) Driver Short to Ground Sensor short to ground
B100A-12 Up Front Sensor (UFS) Driver Short to Battery Sensor short to battery

SRS 52B
CAUTION
T
AF
R
D
DOIQC52BR12047

52B SRS
PASSENGER FRONT IMPACT SENSOR WCH52BTSHOT11019
T
AF
R
DOIQC52BR12007

Code No. B1009-95, B1009-11 & B1009-12 Passenger
D
Probable cause
Front Impact Sensor
front impact sensor • Cross coupling between the (+) and (-)
Fault
Code
B100B-95 Up Front Sensor (UFS) Passenger CrossCoup- Short circuit wiring fault with other
ling
B100B-12 Up Front Sensor (UFS) Passenger Short to Sensor short to ground
Battery
B100B-11 Up Front Sensor (UFS) Passenger Short to Sensor short to battery
Ground

SRS 52B
CAUTION
T
AF
R
D
DOIQC52BR12048

52B SRS
DRIVER SIDE AIRBAG WCH52BTSHOT11020
T
AF
R
DOIQC52BR12013

Code No. B1014-95 , B1014-11 , B1014-12 , B1014-1B &
D
Probable cause
B1014-1A Driver Side Airbag
resistance between the input terminals of the driver side nectors.
airbag • Cross coupling between the (+) and (-)
The trouble causes for each diagnosis code number are of driver side airbag
Fault
Code
B1014-95 Driver Side Airbag CrossCoupled Squib is tested for short circuit wiring fault
with other squibs.
B1014-11 Driver Side Airbag Terminal Short to Squib high side or low side terminal is shor-
B1014-12 Driver Side Airbag Terminal Short to Battery Squib high side or low side terminal is shor-
ted to battery.
B1014-1B Driver Side Airbag Resistance Open Squib is open
B1014-1A Driver Side Airbag Resistance Short Squib is shorted

SRS 52B
Data
List
1 Driver Side Airbag Impedance Replace the if the value is out
1.77-3.49 Ω
range
T
AF
R
D

52B SRS
CAUTION
T
AF
R
D
DOIQC52BR12053

SRS 52B
PASSENGER SIDE AIRBAG WCH52BTSHOT12001
T
AF
R
DOIQC52BR12014

Code No. B1015-95 , B1015-11 , B1015-12 , B1015-1B &
D
Probable cause
B1015-1A Passenger Side Airbag
side airbag • Cross coupling between the (+) and (-)
The trouble causes for each diagnosis code number are of passenger side airbag
Fault
Code
B1015-95 Passenger Side Airbag CrossCoupled Squib is tested for short circuit wiring fault
with other squibs.
B1015-11 Passenger Side Airbag Terminal Short to Squib high side or low side terminal is shor-
B1015-12 Passenger Side Airbag Terminal Short to Squib high side or low side terminal is shor-
B1015-1B Passenger Side Airbag Resistance Open Squib is open
B1015-1A Passenger Side Airbag Resistance Short Squib is shorted

52B SRS
Data
List
1 Passenger Side Airbag Impedance Replace the if the value is out
1.77-3.49 Ω
range
T
AF
R
D

SRS 52B
CAUTION
T
AF
R
D
DOIQC52BR12054

52B SRS
PASSENGER CURTAIN AIRBAG (*IF FITTED) WCH52BTSHOT12002
T
AF
R
DOIQC52BR12019

Code No. B1016-95 , B1016-11 , B1016-12 , B1016-1B &
D
Probable cause
B1016-1A Passenger Curtain Airbag
curtain airbag • Cross coupling between the (+) and (-)
The trouble causes for each diagnosis code number are of passenger curtain airbag
Fault
Code
B1016-95 Passenger Curtain Airbag CrossCoupled Squib is tested for short circuit wiring fault
with other squibs.
B1016-11 Passenger Curtain Airbag Terminal Short to Squib high side or low side terminal is shor-
B1016-12 Passenger Curtain Airbag Terminal Short to Squib high side or low side terminal is shor-
B1016-1B Passenger Curtain Airbag Resistance Open Squib is open
B1016-1A Passenger Curtain Airbag Resistance Short Squib is shorted

SRS 52B
Data
List
1 Passenger Curtain Airbag Imped- Replace the if the value is out
1.77-3.49 Ω
ance range
T
AF
R
D

52B SRS
CAUTION
T
AF
R
D
DOIQC52BR12055

SRS 52B
DRIVER CURTAIN AIRBAG (*IF FITTED) WCH52BTSHOT12003
T
AF
R
DOIQC52BR12018

Code No. B1017-95 , B1017-11 , B1017-12 , B1017-1B &
D
Probable cause
B1017-1A Driver Curtain Airbag
resistance between the input terminals of the driver nectors.
curtain airbag • Cross coupling between the (+) and (-)
The trouble causes for each diagnosis code number are of driver curtain airbag
Fault
Code
B1017-95 Driver Curtain Airbag CrossCoupled Squib is tested for short circuit wiring fault
with other squibs.
B1017-11 Driver Curtain Airbag Terminal Short to Squib high side or low side terminal is shor-
B1017-12 Driver Curtain Airbag Terminal Short to Bat- Squib high side or low side terminal is shor-
tery ted to battery.
B1017-1B Driver Curtain Airbag Resistance Open Squib is open
B1017-1A Driver Curtain Airbag Resistance Short Squib is shorted

52B SRS
Data
List
1 Driver Curtain Airbag Impedance Replace the if the value is out
1.77-3.49 Ω
range
T
AF
R
D

SRS 52B
CAUTION
T
AF
R
D
DOIQC52BR12056

52B SRS
DRIVER LAP PRE-TENSIONER (*IF FITTED) WCH52BTSHOT12004
T
AF
R
DOIQC52BR12016

Code No. B1018-95 , B1018-11 , B1018-12 , B1018-1B &
D
Probable cause
B1018-1A Driver Lap Pre-tensioner
resistance between the input terminals of the driver lap nectors.
pre-tensioner. • Cross coupling between the (+) and (-)
The trouble causes for each diagnosis code number are of driver lap pre-tensioner
Fault
Code
B1018-95 Driver Lap Pre-tensioner Cross Coupled Squib is tested for short circuit wiring fault
with other squibs.
B1018-11 Driver Lap Pre-tensioner Terminal Short to Squib high side or low side terminal is shor-
B1018-12 Driver Lap Pre-tensioner Terminal Short to Squib high side or low side terminal is shor-
B1018-1B Driver Lap Pre-tensioner Resistance Open Squib is open
B1018-1A Driver Lap Pre-tensioner Resistance Short Squib is shorted

SRS 52B
Data
List
1 Driver Lap Pre-tensioner Imped- Replace the if the value is out
1.77-3.49 Ω
ance range
T
AF
R
D

52B SRS
CAUTION
T
AF
R
D
DOIQC52BR12057

SRS 52B
PASSENGER LAP PRE-TENSIONER (*IF FITTED) WCH52BTSHOT12005
T
AF
R
DOIQC52BR12017

Code No. B1019-95 , B1019-11 , B1019-12 , B1019-1B &
D
Probable cause
B1019-1A Passenger Lap Pre-tensioner
lap pre-tensioner. • Cross coupling between the (+) and (-)
The trouble causes for each diagnosis code number are of passenger lap pre-tensioner
Fault
Code
B1019-95 Passenger Lap Pre-tensioner Cross Coupled Squib is tested for short circuit wiring fault
with other squibs.
B1019-11 Passenger Lap Pre-tensioner Terminal Short Squib high side or low side terminal is shor-
to Ground ted to ground.
B1019-12 Passenger Lap Pre-tensioner Terminal Short Squib high side or low side terminal is shor-
to Battery ted to battery.
B1019-1B Passenger Lap Pre-tensioner Resistance Open Squib is open
B1019-1A Passenger Lap Pre-tensioner Resistance Short Squib is shorted

52B SRS
Data
List
1 Passenger Lap Pre-tensioner Imped- Replace the if the value is out
1.77-3.49 Ω
ance range
T
AF
R
D

SRS 52B
CAUTION
T
AF
R
D
DOIQC52BR12058

52B SRS
PASSENGER AIRBAG DEACTIVATION SWITCH WCH52BTSHOT12006
T
AF
R
DOIQC52BR12015

Code No. B1022-95 , B1022-12 , B1022-1B , B1022-1A &
D
Probable cause
B1022-1F Passenger AIrbag Deactivation Switch
airbag deactivation switch. • Cross coupling between the (+) and (-)
The trouble causes for each diagnosis code number are of passenger airbag deactivation switch.
as follows: • Malfunction of SRS-ECU.
Fault
Code
B1022-95 Passenger Airbag Deactivation Switch (PADS) PADS is tested for short circuit wiring fault
Cross Coupled with other switches.
B1022-12 Passenger Airbag Deactivation Switch (PADS) PADS is short to battery
Short to Battery
B1022-1B Passenger Airbag Deactivation Switch (PADS) PADS is open
Open Line
B1022-1A Passenger Airbag Deactivation Switch (PADS) PADS is short to ground
Short Line

SRS 52B
Fault
Code
B1022-1F Passenger Airbag Deactivation Switch (PADS) PADS resistance out of range
Undefined
Data
List
11 Passenger Airbag Deactivation Deactivation switch ON:
Switch Impedance 100 Ohm Replace the if the value is out
Deactivation switch OFF: range
400 Ohm
T
AF
R
D

52B SRS
CAUTION
T
AF
R
D
DOIQC52BR12059

SRS 52B
PASSENGER AIRBAG DEACTIVATION INDICATOR WCH52BTSHOT12007
T
AF
R
DOIQC52BR12023

Code No. B1031-14 & B1031-12 Passenger Airbag Deac-
D
Probable cause
tivation Indicator
airbag deactivation indicator. • Cross coupling between the (+) and (-)
of passenger airbag deactivation indic-
The trouble causes for each diagnosis code number are ator.
as follows: • Malfunction of SRS-ECU.
Fault
Code
B1031-14 Passenger Airbag Deactivation Indicator PADI short to ground or open
(PADI) Short to Ground Or Open
B1031-12 Passenger Airbag Deactivation Indicator PADI short to battery
(PADI) Short to Battery

52B SRS
CAUTION
T
AF
R
D

SRS 52B
T
AF
R
D
DOIQC52BR12060

52B SRS
CAN COMMUNICATION WCH52BTSHOT12008
T
AF
R
DOIQC52BR12010

Code No. U1000-00 , U1003-00 , U1002-00 , U1001-00 ,
D
Probable cause
U1004-00 & U1005-00
These diagnosis codes are output when the Airbag
Control unit detect abnormality in the CAN bus commu- • Malfunction of wiring harnesses or con-
nication with other control unit. nectors.
• CAN network error
The trouble causes for each diagnosis code number are • Malfunction of SRS-ECU.
as follows:
Fault Code PADT-II Display Trouble Causes

U1000-00 CAN Bus OFF 1. Short circuit between CAN_H and CAN_L
2. Short circuit between CAN_H and battery
3. Heavy bus disturbance
U1003-00 Fault of SRS - ECU Commu- AIRBAG ECU message transmission
nication confirmation timeout
U1002-00 Fault of ICM Communica- IP message reception timeout, no message from IP node,
tion 1.CAN network error
2.IP node absence
3. Heavy bus load

SRS 52B
Fault Code PADT-II Display Trouble Causes

U1001-00 Fault of ABS - ECU Commu- ABS message reception timeout
nication 1.CAN network error
2.ABS node absence
3. Heavy bus load
U1004-00 Vehicle Speed Info Invalid Vehicle speed information is invalid
U1005-00 Airbag Warning Lamp Fault Airbag lamp mismatch timeout
Warning lamp status is mismatch
T
AF
R
D

52B SRS
/ 66 SRS MAINTENANCE
CAUTION
T
AF
R
D
DOIQC52BR12061
SRS MAINTENANCE WCH52BMAINT11002
The SRS MUST be inspected by an authorized dealer 10 years after the date of vehicle registration

SRS 52B
SRS MAINTENANCE / 67
SRS WARNING LAMP CHECK
DOIQC52BR12005
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/12
SRS COMPONENT VISUAL CHECK
T
AF
R
DOIQC52BR12030
D
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/6 )

52B SRS
SRS Control Unit (SRS-ECU)
DOIQC52BR12024
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
visual check (refer to 52B/76 )

Air Bag Modules, Steering Wheel and Clock Spring
T
2. Check connector for damage, and terminals for deformation or rust. Replace SRS-ECU if it fails
AF
1. Remove the airbag modules, steering wheel and clock spring (refer to 52B/81 )
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.
R
D
DOIQC52BR12025
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

SRS 52B
SRS MAINTENANCE / 69
DOIQC52BR12026
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
E
Harness auto cruise
Harness SRS
7. Visually check the clock spring case for damage.
T
AF
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.
R
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
D
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/81 )
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.

52B SRS
INSTRUMENT PANEL WIRING HARNESS/FLOOR WIRING HARNESS
DOIMC52BR07002
1. Check connector for poor connection.

2. Check harness for binds, connector for damage and terminals for deformation.
Symbol Description
A Passenger airbag* (if so equipped)
B
C
T
Instrument panel wiring harness
Driver airbag
AF
D Floor wiring harness
E SRS ECU
NOTE :
REPLACE ANY CONNECTORS OR HARNESS THAT FAIL THE VISUAL INSPECTION (Refer to page
52B/6 ).
CAUTION
R
The SRS may not activate if SRS harnesses or connectors are damaged or improperly connected,
which could result in serious injury or death to the vehicle's driver or front passenger.
POST INSTALLATION INSPECTION

D
DOIQC52BR12005
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 WCH52BTSHOT11002)

SRS 52B
POST COLLISION DIAGNOSIS / 71
POST COLLISION DIAGNOSIS WCH52BPOSTC11002
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/12 )
NOTE
If the battery power supply has been disconnected or destructed 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/12 )
REPAIR PROCEDURE
T
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/76 )
AF
• Driver's side air bag module (refer to 52B/81 )
• Seat belt with pre-tensioner (refer to 52B/100 )
2. Check the following parts and replace if there are any malfunctions
• Clock spring (refer to 52B/81 )
• 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.
R
3. Check steering wheel for noise, binds or difficult operation and excessive free play.
3. Check harnesses for binding, connectors for damage, poor connections and terminal for deform-
ation.
D
When Side and Curtain Airbags are Operates in a Collision

1. Replace the following parts with new ones.
• SRS-ECU (Refer to 52B/76 )
• Front seatback pad and frame assembly (Refer to 52B/76 )
• Curtain air bag module (Refer to 52B/76 )
• Side impact sensor (Refer to 52B/76 )
• Headlining (Refer to GROUP 52A - Headlining)
• Front pillar trim, upper centre pillar trim, rear pillar trim (Refer to GROUP 52A - Interior Trim
)
2. Check the wiring harness for binding, the connector for damage, and the terminal for deformation.
When Seat Belt Pre-Tensioner Operates in a Collision
1. Replace the following parts
• SRS-ECU (refer to 52B/76 )
• Seat belt with pre-tensioner (refer to 52B/100 )
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)

52B SRS
/ 72 POST COLLISION DIAGNOSIS
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 )
DOIQC52BR12024
1. SRS ECU
T
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
AF
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.
R
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.
D
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.
7. Front Impact Sensor
7.1 Check the front impact sensor for damage or deformation.
7.2 Check the connector damage, the terminal for cracks or deformation.
8. Front Seat Assembly (with built-in side air bag module)
8.1 Check that the side-airbag module deployment part of the seat is normal.
8.2 Check the connector for damage, the terminal for deformation and the harness binding.
9. Side Impact Sensor
9.1 Check the center pillar and quarter trim lower for deformation.
9.2 Check the side impact sensor for dent, crack, deformation or rust.
10. Curtain Airbag Module
10.1 Check that the curtain airbag deployment part of the headlining is normal.

SRS 52B
INDIVIDUAL COMPONENT SERVICE / 73
10.2 Check the inflator surface for cracks, dents, or deformations.

INDIVIDUAL COMPONENT SERVICE WCH52BICOMP11002
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/76 to page 52B/102 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.
(2) If the SRS components and seat belts with pre-tensioner are removed for the purpose of check,
sheet metal repair, painting, etc., they should be stored in a clean, dry place until they are rein-
stalled.
WARNING / CAUTION LABEL

T WCH52BSASSY11001
AF
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.
R
D
NOTE:
2: if so equipped

52B SRS
/ 74 WARNING / CAUTION LABEL
T
AF
R
D
DOIMC52BR07005
Symbol Description

SRS 52B
WARNING / CAUTION LABEL / 75
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
T
AF
R
D

52B SRS
/ 76 SRS AIR BAG CONTROL UNIT (SRS-ECU)
SRS AIR BAG CONTROL UNIT (SRS-ECU) WCH52BSASSY11002
T
AF
R
DOIQC52BR12028
D
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/9 .
(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.

SRS 52B
SRS AIR BAG CONTROL UNIT (SRS-ECU) / 77
• 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 0.9 kgm (9 Nm, 6.51 ft.lbs) ± 0.15 kgm (1.5 Nm, 1.08 ft.lbs)
T
AF
R
D

52B SRS
1. NEGATIVE (-) BATTERY CABLE FROM THE

CAUTION
After the ignition switch has been placed at the
LOCK position and the negative (-) terminal of
the battery has been disconnected, wait for at
least 5 min. before starting work. Wind a tape
around the disconnected (-) terminal for insula-
tion.
DOIQC52BR12030 Symbol Description
A Positive (+) terminal
B Insulating tape negative (-) terminal
C Battery
3. DISCONNECTION FOR THE AIR BAG

CONTROL UNIT AND THE HARNESS BODY
T
CONNECTOR
• Press the stopper lock.
• Push the lock lever and remove outward the
AF
harness side connector for disconnection.
Symbol Description
A Air bag control unit
B Stopper lock
C Lock lever
R
CAUTION
• Do not use excessive force to push the
lock lever and
D
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.

SRS 52B
SRS AIR BAG CONTROL UNIT (SRS-ECU) / 79

5. AIR BAG CONTROL UNIT INSTALLATION
CAUTION
The SRS may not active if Air Bag Control unit
is not installed properly, which could result in
serious injury or death to the vehicle's driver or
front passenger in case of accident.
4. CONNECTION FOR THE EARTHING

HARNESS OF THE AIR BAG CONTROL UNIT
CAUTION
At the grounding point, ensure that the installa-
tion sequence of the Air Bag Control Unit include
the connection of the earthing harness. The SRS
will not function if Air Bag Control Unit is not
installed properly, which could result in serious
injury or death to the vehicle's driver or front
passenger in case of accident.
T 1. Fix the Air Bag Control Unit (C) to the floor

bolt hole.
2. Put the earthing harness (B) on the floor bolt
AF
hole.
3. Tighten the bolts with earthing harness (B)
between bolt (A) and Air Bag Control Unit
(C).
Symbol Description
R
A Bolt
B Earthing harness
C Air Bag Control Unit
DOIQC52BR12029
D
T1 0.9 kgm (9 Nm, 6.51 ft.lbs) ± 0.15

3. CONNECTION FOR THE AIR BAG CONTROL

UNIT AND THE HARNESS SIDE CONNECTOR
1. Press the stopper lock.
2. Push inward the harness side connector and
push the lock lever to connect the harness
side connector securely.
Symbol Description
A Air Bag Control Unit
B Stopper lock
DOIHC52BR06006 C Lock lever

52B SRS
POST INSTALLATION INSPECTION

1. Reconnect the negative battery terminal.
Turn the ignition key to the “ON” position.
Does the SRS warning lamp illuminate for
about 4.5 seconds, and then extinguished
for at least 30 sec.
If yes. SRS system is functioning properly. If
no, consult page WCH52BTSHOT11002 -
Troubleshooting
INSPECTION
• Check the Air Bag Control Unit dents and
DOIQC52BR12027 cracks or deformation.
• Check connector for damage, and terminals
for deformation.
• Make sure no surrounding part (example
carpet, harness, handbrake cables, console
box etc.) touching / in contact with Air Bag
Control Unit. The surrounding clearance for
SRS-ECU must be minimum 5 mm (0.2 in)
T •
around.
Make sure no rubber sealant or any part
between the SRS-ECU and floor consule in-
AF
stallation.
CAUTION
If a dent, crack and deformation replace the Air
Bag Control unit with a new one.
R
D

SRS 52B
AIR BAG MODULE AND CLOCK SPRING / 81
AIR BAG MODULE AND CLOCK SPRING WCH52BSASSY11003
T
AF
R
DOIQC52BR12031
D

52B SRS
/ 82 AIR BAG MODULE AND CLOCK SPRING
CAUTION
(1) Disconnect the battery (-) terminal and wait for 5 minutes or more before starting work. The
disconnected battery terminal should be covered with tape to insulate it.
(2) Never attempt to disassemble or repair the air bag module or clock spring.
If faulty, replace it.
(3) Do not drop the air bag module or clock spring or allow contact with water, grease or oil.
Replace it if a dent, or crack deformation are detected.
(4) The air bag module should be stored and placed on a flat surface so that the pad surface is facing
upward.
Do not place anything on top of it.
(5) Do not expose the air bag module to temperature over 85 °C (185 °F).
(6) When the driver's side and front passenger's side air bags(1) have been deployed, the air bag
(2)
modules (driver's side and front passenger's side ) should be replaced with new modules. When
(3)
a side air bag has been deployed, the front seat back assembly (driver's seat or passenger's
seat) should be replaced with a new assembly.
(7) After deployment of an air bag, replace the clock spring with a new one.
(8) Wear gloves and safety glasses when handling an air bag that has already deployed.
• After setting the steering wheel and the front wheels to the straight ahead position, remove the
ignition key.
Clock Spring removal steps
T
• Pre-installation inspection (Refer to Installation of Steering GROUP 37A-STEERING)
AF
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
R
• Pre-installation inspection
Air Bag Module removal steps
1. Connector for the negative (-) battery cable to the battery
D
2. Air bag module

T1 3.3 - 4.9 kgm (33 - 49 Nm, 23.87 - 35.44 ft.lbs)
T2 0.7 - 1.1 kgm (7 - 11 Nm, 5.06 - 7.96 ft.lbs)
T3 0.069 kgm (0.69 Nm, 0.5 ft.lbs) ± 0.015 kgm (0.15 Nm, 0.11 ft.lbs)
NOTE:
(1) if so equipped
(2) if so equipped
(3) if so equipped

SRS 52B
1. NEGATIVE (-) BATTERY CABLE FROM THE

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.
DOIQC52BR12030
Symbol Description
A Battery cable
B Insulating tape
C Battery
DRIVER FRONT AIR BAG MODULE REMOVAL

1. Untighten the air bag module mounting
T screws (torque screws) at the side of the

steering wheel.
NOTE
AF
Do not remove the screws from the holders.
Symbol Description
1 Wheel steering
2 Mounting screw
DOINC37AR09001 3 Torque screw
R
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
D
spread it open. Use a flat-tipped screwdriver,

as shown in the figure at the left, to pry so
as to remove the connector gently.
CAUTION
(1) When disconnecting the air bag module
clock spring connector, take care not to
apply excessive force to it.
(2) The removed air bag module should be
stored in clean, dry place with the pad
DOIJC52BR04080
cover face up.
Symbol Description
1 Lock
2 Flat-tapped screwdriver
CLOCK SPRING REMOVAL

CAUTION
The removed clock spring should be stored in a
clean, dry place clock spring face up.

52B SRS
1. Marking (A) the steering wheel as shown in

the illustration.
DOIJC37AL06009
2. Loosen nut steering shaft shown in illustra-

tion.
T
AF
DOINC37AR09017
3. Use special tool MB990803 to remove steer-

ing wheel from shaft.
4. Disconnect 4 connectors from column switch
R
harness.
• Connector column switch (wiper side)
• Connector column switch (signal side)
• Connector column switch (int)
D
• Connector column switch (horn and SRS

side).
INSPECTION
CLOCK SPRING
DOINC37AR09018
If any malfunction is found in the following in-
spections, replace the clock spring with a new
one
1. Check the connectors and protective tubes
for damage and the terminal for deforma-
tion.
2. Check the case for damage.
3. Check that the continuity exists between the
following connector terminals.
• Continuity between pin no.1 (Clock spring
C-20) and pin no 36 (I/P(B)-Body(B) connector
C-15)

SRS 52B
• Continuity between pin no.2 (Clock spring

C-20) and pin no 37 (I/P(B)-Body(B) connector
C-15)
PRE-INSTALLATION INSPECTION
1. When installing the new air bag module and
clock spring, refer to INSPECTION section
(refer on next page).
DOIQC52BR12027
2. Connect the battery (-) terminal and turn the

ignition on.
Symbol Description
T A
B
Battery cable
Insulating tape
AF
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
DOIQC52BR12030
open circuit of air bag module.
R
5. Turn the ignition key to the “LOCK” position,

disconnect the negative battery cable and
tape the terminal.
CAUTION
D

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-
dental air bag deployment will result in ser-
ious personal injury.

52B SRS
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. Check the resistance at the squib connector.
OK: 2.01~4.24 Ω
6. 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.
T 1.1 Check connectors and cable for damage,

terminal for deformities or no continu-
ity.
AF
1.2 Visually check the housing damage.
Symbol Description
A Window
B Mating marks
DOIMC52BR07013
C Harness horn
R
D Harness SRS
CLOCK SPRING CHECK
D
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.

SRS 52B

5. CLOCK SPRING INSTALLATION
1. Make sure front wheels are in straight posi-
tion.
Symbol Description
A Window
B Mating marks
C Harness horn
D Harness SRS
DOIMC52BR07013
2. Turn the clock spring to clock wise fully, and
then turn it back to approx. 3 1/8 turns
counter clockwise to align the mating mark.
Make sure that all connector are at 6 o'clock
(Neutral) position.
CAUTION
If the clock spring's mating mark is not properly
T
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
AF
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.
R
(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
D
be damaged due to improper cable routine

and installation.
3. STEERING WHEEL INSTALLATION

1. Before installing the steering wheel, be sure
to first turn the vehicle's front wheels to the
straight-ahead position and align the mating
mark and “NEUTRAL” accordingly to the in-
stallation service point for clock spring.
CAUTION
(1) During installation of the steering wheel,
ensure that the cable of the clock spring
does not become caught or tangled.
(2) The clock spring flat cable or terminal
can be damaged due to improper cable
routine and installation.
2. After clamping, turn the steering wheel all
the way in both directions to confirm that
steering is normal.

52B SRS
2. DRIVER FRONT AIR BAG MODULE

INSTALLATION
1. Connect the air bag module connector se-
curely.
2. Place the air bag module assembly in position
and re-tighten torque bolt from rear side.
Standard Value:
Tightening torque 0.7 kgm (7 Nm, 5.06 ft.lbs)
~1.1 kgm (11 Nm, 7.96 ft.lbs)
CAUTION
Never connect battery or switch ignition ON
while installing the air bag module.
2. POST-INSTALLATION INSPECTION
1. After installing the clock spring, the steering
wheel, the column cover and the air bag
module, check steering wheel for noise, binds
or operation difficulty. Turn the steering
T wheel right and left lightly to see its smooth

operation, and free from abnormal noise.
2. Reconnect the negative battery terminal.
AF
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
WCH52BTSHOT11001.
R
D

SRS 52B
INSPECTION
DRIVER AIR BAG MODULE / FRONT PASSENGER
3
AIR BAG MODULE CHECK
ule with a new one. Dispose the old accord-
ing to the specified procedure.
CAUTION
ance of the air bag modules (squib) even if
cuit resistance is measured with a tester,
accidental air bags deployment will result in
serious personal injury.
3. Check connectors for damage, terminals for
deformation, and harness for binds.
4. Check air bag inflator case for dents, cracks
T
or deformation.
5. Install the driver front air bag module to
steering wheel to check fit or alignment with
AF
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.
R
D
NOTE:
3: if so equipped

52B SRS
/ 90 FRONT PASSENGER AIR BAG MODULE
FRONT PASSENGER AIR BAG MODULE WCH52BSASSY11004
T
AF
R
DOIQC52BR12032
Front passenger's air bag module removal steps

• Pre-installation inspection (Refer to Installation of Instrument Panel Assembly MODULE 1.10 —
D
GROUP 52A)
1. Connection for the negative (-) battery cable to the battery
2. Instrument panel
3. Front passenger's air bag module
• Pre- installation inspection
T1 0.6 kgm (6 Nm, 4.34 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)
T2 1.6 kgm (16 Nm, 11.57 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs)

SRS 52B
FRONT PASSENGER AIR BAG MODULE / 91
1. NEGATIVE (-) BATTERY TERMINAL FROM

THE BATTERY DISCONNECTION
1. Disconnect the negative (-) battery terminal
and tape the terminal.
CAUTION
the battery terminal before doing any fur-
ther work.
DOIQC52BR12030
Symbol Description
A Positive (+) battery terminal
B Negative (-) battery terminal
covered with insulating tape
C Battery
REMOVAL OF THE FRONT PASSENGER'S AIR

BAG MODULE
T 1. Remove the Instrument Panel Assy (refer to

Group 52 Interior)
AF
2. Remove 4 pieces bolt of the CCB bracket
mounted at the cross beam.
R
D
DOIQC52BR12034
The location of the bolts mounting position

are shown in the illustration.
Item Description
A Passenger Airbag Module
B CCB bracket
DOIQC52BR12040

52B SRS
3. Disconnect the Passenger airbag harness

connector.
DOIQC52BR12035
4. Remove the Instrument Panel Assy.
T
AF
DOIQC52BR12036
5. Remove 4 pieces bolt of side bracket moun-

ted to Instrument Panel Assy.
R
D
DOIQC52BR12037
The location of the bolts mounting position

are shown in the illustration.
Item Description
A Passenger Airbag Module
B Side bracket
DOIQC52BR12033

SRS 52B
6. Open the front passenger's air bag from up-

per side of the instrument panel by using a
stick to prevent instrument panel from dents,
cracks or deformities (as shown in the figure).
DOIQC52BR12038
7. Remove the Passenger airbag module.

CAUTION
(1) When disconnecting the air bag module
clock spring connector, be careful not to
apply excessive force to it. DO NOT for-
get to unlock the lock lever in the first
T
place.
(2) Be careful when handling the removed
front passenger's air bag. Ensure to use
AF
one hand to hold the top cover and
other hand to hold the inflater case. This
is to prevent the air bag module from
DOIQC52BR12039
dropping which may cause injury to the
carrier.
stored in clean, dry place with the pad
R
cover face up.

8. When disconnecting the dash harness con-
nector (B) from the front passenger's air bag
D
module, push the lock lever (A) outward to

spread it open by using a flat-tip screwdriver
(C) (as shown in the figure).
Symbol Description
A Lock lever
B Harness connector
C Flat-tip screwdriver
DOIMC52BR10040

52B SRS
9. Disconnect the harness connector completely

from the front passenger's air bag module
gently.
1. When installing the front passenger air bag
module, refer to INSPECTION section.
1. PASSENGER FRONT AIR BAG MODULE

INSTALLATION
DOIMC52BR10032
1. Connect the air bag module connector se-
curely.
2. Place the air bag module assembly in position
and re-tighten torque bolt from rear side.
Standard Value:
Tightening torque 0.5 kgm (5 Nm, 3.62 ft.lbs)
~0.7 kgm (7 Nm, 5.06 ft.lbs)
T CAUTION
DO NOT connect battery while connecting
or disconnecting the air bag module.
AF
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
R
wheel, the column cover and the air bag

module, check steering wheel for noise, binds
or operation difficulty. Turn the steering
D
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
6 times, and then turn off permenantly? If
DOIQC52BR12027 this condition does not meet. Refer to SRS
WARNING LAMP INSPECTION WCH52BT-
SHOT11001.

SRS 52B
INSPECTION
FRONT PASSENGER'S AIR BAG MODULE
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
ance of the air bag modules (squib) even if
DOIQC52BR12041
cuit resistance is measured with a tester,
accidental air bags deployment will result in
serious personal injury.
3. Check connectors for damages, terminals for
deformities, and harness for binds.
4. Check air bag inflator case for dents, cracks
T 5.
or deformities.
Install the front passenger air bag module
to instrument panel to check the fitting.
AF
CAUTION
If dents, cracks or deformities are discovered
in the air bag module, replace it with a new
one.
Symbol Description
R
B Front passenger's airbag mod-

ule
D

52B SRS
/ 96 CURTAIN AIR BAG MODULE
CURTAIN AIR BAG MODULE WCH52BSASSY12004
T
AF
R
DOIQC52BR12067
D

SRS 52B
CURTAIN AIR BAG MODULE / 97
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 curtain air bag module. If damaged, replace it with
new one(s).
(3) Handle the air bag module with sufficient caution, and do not drop the module or allow contact
with water, oil, or others. If denting, cracking, or deformation is discovered, replace it with new
one(s).
(4) Store the air bag module on a flat surface. Also, do not put anything on it.
(5) Do not store the air bag modules in a place more than 93°C.
(6) After the curtain air bag deployment, replace the curtain air bag module with a new part.
(7) When discarding the air bag module, make sure to deploy the air bag before the disposal (Refer
to 52B/122 )
(8) Put on gloves and safety glasses when handling deployed air bags.
• Headlining removal and installation (Refer to GROUP 52A — Headlining).
Removal steps
• Negative (-) battery cable connection
1. Disconnect the battery (-) terminal
2. Disconnect Curtain Air bag harness connector
3. Curtain Airbag module
T
AF
T1: 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm, 0.72 ft.lbs) (8 pieces M6 bolt washer assembled)
R
D

52B SRS
/ 98 CURTAIN AIR BAG MODULE
REMOVAL SERVICE POINTS WCH52BSPROC12004
FRONT IMPACT SENSOR CONNECTOR REMOVAL

1. Release the connector locking.
Pull the harness connector to release the
harness connector.
POST-REMOVAL INSPECTION
CAUTION
(1) Never use an electric tester to diagnose the
air bag module circuit. Never attempt to
disassemble the air bag module.
DOIQC52BR12068
(2) Never use an electric tester to diagnose the
air bag module circuit. Never attempt to
disassemble the air bag module.
stored in a clean, dry place.
(4) When discarding the air bag module, discard
after deploying the air bag as specified in
the service procedure.
T ITEM
A
DESCRIPTION
Part label
AF
B Harness connector locking
position
1. Before the installation, check the air bag
module (Refer to
R
NOTE
Even when installing a new air bag module,
perform an inspection before the installation.
2. Connect the negative (-) battery terminal.
D
3. Read the diagnosis code, and check that the

system is normal except the air bag module
open circuit.
4. Turn the ignition switch to the LOCK (OFF)
position.
INSTALLATION INSPECTION
CAUTION
(1) Take care not to contort the curtain air bag
when installing it.
(2) Do not trap the air bag with the peripheral
parts.
(3) Do not trap the strap with the front pillar
trim clip or others.
(4) Ensure the harness connector firmly connec-
ted to the Air bag module.

SRS 52B
CURTAIN AIR BAG MODULE / 99
1. Connect the battery (-) terminal
2. Turn the ignition switch to “ON” position.
extinguished for at least 30 seconds. If this
WCH52BTSHOT11002.
DOIQC52BR12027
T
AF
R
D

52B SRS
/ 100 SEAT BELT WITH PRE-TENSIONER
SEAT BELT WITH PRE-TENSIONER WCH52BSASSY11005
T
AF
R
DOIQC52BR12043
D

SRS 52B
SEAT BELT WITH PRE-TENSIONER / 101
CAUTION
(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.
• Rear trim side sill assy removal and installation (Refer to GROUP 52A — Trims Lower).
• Front trim side sill assy removal and installation (Refer to GROUP 52A — Trims Lower).
• Trim center pillar lower assy removal and installation (Refer to GROUP 52A — Trims Lower).
Removal steps
2. Seat belt garnish
3. Seat belt with pre-tensioner
T
4. Center pillar upper trim assy (Refer to GROUP 52A — Trims Upper)
AF
5. Disconnect pre-tensioner connector
NOTE :
After provisionally tightening the seat belt assembly mounting bolt in every installation location,
T1: 3.43 - 5.39 kgm (34.3 - 53.9 Nm, 24.81 - 38.99 ft.lbs)
R
D

52B SRS
/ 102 SEAT BELT WITH PRETENSIONER
SEAT BELT WITH PRETENSIONER

WCH52BSPROC11010

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.
DOIQC52BR12027 3. Turn the ignition switch to “ON” position.
WCH52BTSHOT11002.
INSPECTION
T 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.
AF
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
R
result in serious personal injury.

1. Check seat belt pre-tensioner for dents,
cracks or deformation.
D
2. Check connectors for damage, and terminals

for deformation, and harness for binds.

SRS 52B
SIDE AIRBAG MODULE / 103
SIDE AIRBAG MODULE WCH52BSASSY12001
T
AF
R
DOIQC52BR12044
D

52B SRS
/ 104 SIDE AIRBAG MODULE
CAUTION
(2) Never attempt to disassemble or repair the air bag module. If faulty, replace it with new one(s).
(3) Handle the front seat assembly (with side-airbag module) with sufficient caution, and do not
drop the assembly or allow contact with water, oil, or others. If denting, cracking, or deformation
is discovered, replace it with new one(s).
(4) Store the front seat assembly (with side-airbag module) on a flat surface. Also, do not put any-
thing on it.
(5) Do not store the front seat assembly (with side-airbag module) in a place where the temperature
exceeds 93°C.
(6) After the side-airbag deployment, replace the front seat assembly (with side-airbag module)
with the new one.
(7) Put on gloves and safety glasses when handling deployed air bags.
(8) When discarding the air bag module, make sure to deploy the air bag before the disposal (Refer
to 52B/122 ).
Removal steps
2. Disconnect Side Airbag connector
3. Front Seat Assy (Refer to GROUP 52A — Front Seat)
T
AF
R
D

SRS 52B
SIDE AIRBAG MODULE / 105
PRE-REMOVAL INSPECTION
CAUTION
• When replacing the side-airbag module, re-
place the front seat assembly.
• Never use an electric tester to diagnose the air
bag module circuit. Never attempt to disas-
semble the air bag module.
• Store the removed front seat assembly in a
clean and dry place.
• When discarding the air bag module, discard
after deploying the air bag as specified in the
service procedure (Refer to 52B/114
1. When installing a new seat belt with side
airbag module refer to “INSPECTION”
T
NOTE
Even when installing a new front seatback
pad and frame assembly (with side-airbag
module), perform an inspection before the
AF
installation.
2. Connect the negative (-) battery terminal.
3. Connect the PADT-II. Read the diagnosis
DOIQC52BR12027
code, and check that everything is normal
except the air bag module open circuit.
4. Turn the ignition switch to the LOCK (OFF)
R
position.
D

WCH52BTSHOT11002.
DOIQC52BR12027

52B SRS
/ 106 FRONT IMPACT SENSOR
FRONT IMPACT SENSOR WCH52BSASSY12003
T
AF
R
DOIQC52BR12065
D
CAUTION
(2) Never attempt to disassemble or repair the front impact sensor. If damaged, replace it with new
one(s).
(3) Handle the front impact sensor with sufficient caution, and do not drop or subject the sensor
to impact or vibration. If there is a dent, crack, or deformation, replace with a new sensor.
(4) After the driver/passenger air bag deployment, replace with a new sensor.
Removal steps
2. Disconnect Side Impact Sensor connector (LH/RH)
3. Front Impact Sensor (LH/RH)
T1: 1.05 kgm (10.5 Nm, 7.59 ft.lbs) ± 0.16 kgm (1.6 Nm, 1.16 ft.lbs)

SRS 52B
FRONT IMPACT SENSOR / 107
FRONT IMPACT SENSOR CONNECTOR REMOVAL

1. Release the connector locking (red).
DOIQC52BR12063
2. Pull the harness connector in upward posi-

tion.
Even when installing a new front impact sensor,
perform an inspection before the installation
(Refer to the item on inspection).
T CAUTION
If the front impact sensor is not securely and
correctly installed, the correct operation of front
AF
air bag is prevented.
DOIQC52BR12064
Connect the connector securely. Check the right

impact sensor is being installed.
R
ITEM DESCRIPTION
A Part label
D
position
DOIQC52BR12066

52B SRS
/ 108 FRONT IMPACT SENSOR
WCH52BTSHOT11002.
DOIQC52BR12027
T
AF
R
D

SRS 52B
SIDE IMPACT SENSOR / 109
SIDE IMPACT SENSOR WCH52BSASSY12002
T
AF
R
DOIQC52BR12062
D
CAUTION
(2) Never attempt to disassemble or repair the side impact sensor. If damaged, replace it with new
one(s).
(3) Handle the side impact sensor with sufficient caution, and do not drop or subject the sensor to
impact or vibration. If there is a dent, crack, or deformation, replace with a new sensor.
(4) After the side/curtain air bag deployment, replace with a new sensor.
• Rear trim side sill assy removal and installation (Refer to GROUP 52A — Trims Lower).
• Front trim side sill assy removal and installation (Refer to GROUP 52A — Trims Lower).
• Trim center pillar lower assy removal and installation (Refer to GROUP 52A — Trims Lower).
Removal steps
2. Disconnect Side Impact Sensor connector (LH/RH)
3. Front Impact Sensor (LH/RH)

52B SRS
/ 110 SIDE IMPACT SENSOR
T1: 1.05 kgm (10.5 Nm, 7.59 ft.lbs) ± 0.16 kgm (1.6 Nm, 1.16 ft.lbs)
T
AF
R
D

SRS 52B
SIDE IMPACT SENSOR / 111
SIDE IMPACT SENSOR CONNECTOR REMOVAL

1. Release the connector locking (red).
DOIQC52BR12063
2. Pull the harness connector in upward posi-

tion.
Even when installing a new side impact sensor,
perform an inspection before the installation
(Refer to the item on inspection).
T CAUTION
If the side impact sensor is not securely and
correctly installed, the correct operation of
AF
side/curtain air bag is prevented.
DOIQC52BR12064
Connect the connector securely. Check the right

impact sensor is being installed.
R
ITEM DESCRIPTION
A Part label
D
position
DOIQC52BR12066

52B SRS
/ 112 SIDE IMPACT SENSOR
WCH52BTSHOT11002.
DOIQC52BR12027
T
AF
R
D

SRS 52B
PASSENGER AIR BAG DEACTIVATION SWITCH / 113
PASSENGER AIR BAG DEACTIVATION SWITCH WCH52BSASSY12005
T
AF
R
DOIQC52BR12069
D
CAUTION
(2) Never attempt to disassemble or repair the side impact sensor. If damaged, replace it with new
one(s).
(3) Handle the side impact sensor with sufficient caution, and do not drop or subject the sensor to
impact or vibration. If there is a dent, crack, or deformation, replace with a new sensor.
(4) After the side/curtain air bag deployment, replace with a new sensor.
• Rear Instrument Panel Assy removal and installation (Refer to GROUP 52A — Instrument Panel
Assy).
Removal steps
2. Passenger Air Bag Deactivation Switch

52B SRS
/ 114 UN-DEPLOYED AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL
SIDE IMPACT SENSOR CONNECTOR REMOVAL

1. Use the ornament remover to pry out the
switch from the Instrument Panel Assy as
DOIQC52BR12071
INSPECTION
Check the switch resistance value.
Switch status Resistance value

Deactivate 100 Ω
Activate 400 Ω
T If resistance deviates from the above, replace the

switch.
AF
DOIQC52BR12070
R

D

WCH52BTSHOT11002.
UN-DEPLOYED AIR BAG MODULE

AND SEAT BELT PRE-TENSIONER
DOIQC52BR12027 DISPOSAL WCH52BDSPOS11003
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.

SRS 52B
UN-DEPLOYED AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL / 115
DEPLOYMENT INSIDE THE VEHICLE

1. Move the vehicle to an isolated spot.
2. Disconnect the negative (-) and positive (+)
battery cables from thr battery terminals,
and then remove the battery from the
vehicle.
CAUTION
Wait at least 60 seconds after disconnecting
the battery cables before doing any further
work (refer to WCH52BGINFO11002— SRS
Service Precaution)
3. Deploy each air bag module and seat belt
pre-tensioner in the following procedures
Driver's air bag module

1. Remove the steering column cover lower.
2. Remove the connection between the clock
spring connector (red) and the instrument
panel wiring harness connector.
T
AF
DOIMC52BR07038
NOTE
If the clock spring connector is disconnected
R
from the instrument panel wiring harness,

both electrodes of the clock spring connector
will be automatically shorted to prevent un-
D
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

52B SRS
4. Connect the SRS air bag adapter harness to

the clock spring connector and pull the de-
ployment wires out of the vehicle.
Symbol Description
A Clock spring connector
B SRS air bag adapter harness
C Deployment wires
DOIMC52BR07017
5. Fully close all door windows, close the doors

and place a cover over the vehicle to minim-
ize the amount of noise.
Symbol Description
A Cover
B Deployment wires
T CAUTION
If the glass is damaged, it may break, so the
AF
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.
R
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
D
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.

SRS 52B
Seat belt pre-tensioner

1. Remove the center pillar lower trim (refer to
GROUP 52A — Center pillar lower trim)
Symbol Description
Seat belt pre-tensioner con-
A
nector
B SRS ECU connector
2. <For Driver's Side> Remove the connection
between the seat belt pre-tensioner and the
SRS-ECU connector.
DOIMC52BR07019 NOTE
If the seat belt pre-tensioner connector is
disconnected from the SRS-ECU, both elec-
trodes of the seat belt pre-tensioner connect-
or will be automatically shorted to prevent
unintended deployment of the seat belt pre-
tensioner due to static electricity, etc.
3. Connect two wire, each six meters or longer,
T to the two leads of SRS air bag adpater har-

AF
should be connected to each other (short
circuited), to prevent sudden unexpected
deployment of the seat belt pre-tensioner.
Symbol Description
R
B Insulation tape
C Connection
DOIMC52BR07016
D Deployment wires
D
4. Connect the seat belt connector to SRS air

bag adapter harness and pass the deploy-
ment wires out of the vehicle
Symbol Description
B Seat belt pre-tensioner
C Deployment wires
DOIMC52BR07020

52B SRS
5. Fully close all door windows, close the doors

and place a cover over the vehicle to minim-
ize the amount of noise.
Symbol Description
A Cover
B Deployment wires
CAUTION
If the glass is damaged, it may break so the
car must be covered.
DOIMC52BR07018 the vehicle as possible and connect the wires
to the terminals of the battery removed from
the vehicle. Deploy the seat belt pre-tension-
er.
CAUTION
• Before deploying the seat belt pre-tension-
er in this manner, first check to be sure that
there is no one in or near the vehicle. Wear
T safety glasses.
• The deployment of the seat belt pre-ten-
sioner makes the inflator very hot. Before
AF
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.
R
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 WCH52BDSPOS003)
D
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 WCH52BGINFO11002)
2. Deploy each air bag module, seat belt pre-
tensioner in the following procedures.

SRS 52B
Driver's side air bag module

1. Remove the driver's side air bag module from
the vehicle (refer to WCH52BSASSY058 —
SRS Service Precaution)
CAUTION
The driver's side air bag module should be
stored on a flat surface and placed so that
the air bag deployment surfaces are facing
upward. Do not place anything on top of
them.
2. Connect two wires, each six meters or longer,
deployment of the driver's side air bag.
Symbol Description
T
B Deployment wires
C Connection
AF
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
R
old tyre wheel assembly, and connect it to

the driver's side air bag module.
Symbol Description
D
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.

52B SRS
6. Place three old tyres without wheels on top

of the tyre secured to the driver's side air bag
module.
Symbol Description
A Tyres without wheels
B Deployment wires
DOIMC52BR07024

the driver's side air bag module as possible
and connect the wires to the terminals of the
battery removed from the vehicle. Then de-
ploy
Symbol Description
T CAUTION
A Deployment wires
AF
• 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
R
deploy when the procedures above are fol-

lowed, do not go near the module. Contact
your local distributor.
D
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 WCH52BDSPOS003)
Seat belt pre-tensioner
1. Remove the seat belt pre-tensioner from the
vehicle (refer to WCH52BSASSY059)
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.

SRS 52B
2. Connect two wires, each six meters or longer,

deployment of the seat belt pre-tensioner.
Symbol Description
B Insulation tape
C Connection
DOIMC52BR07016
D Deployment wires
3. Take the SRS air bag adapter harness that is
connected to the wires, pass it beneath the
old tyre wheel assembly, and connect it to
the seat belt pre-tensioner.
Symbol Description
T
A Seat belt pre-tensioner
B Deployment wires
4. Pass the wires through the hole on the seat
AF
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
R
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
D
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

52B SRS
/ 122 AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURE
5. Place the three old tyres without wheels on

top of the tyre secured to the seat belt pre-
tensioner.
Symbol Description
A Tyres without wheels
B Deployment wires
DOIMC52BR07024

the seat belt pre-tensioner as possible and
connect the wires to the terminals of the
battery removed from the vehicle, and de-
ploy
Symbol Description
T CAUTION
A Deployment wires
AF
• 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
R
when the procedures above are followed,

do not go near the seat belt pre-tensioner.
Contact your local distributor.
D
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 WCH52BDSPOS003)
AIR BAG MODULE AND SEAT BELT

PRE-TENSIONER DISPOSAL
PROCEDURE WCH52BDSPOS11002
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.

SRS 52B
DEPLOYED AIR BAG MODULE OR OPERATED SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES / 123
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
T areas whenever possible. If anyone is

nearby, give warning of the impending
noise.
AF
(4) Suitable ear protection should be worn by
personnel performing these procedures or
by people in the immediate area.
DEPLOYED AIR BAG MODULE OR

OPERATED SEAT BELT
R
PRE-TENSIONER DISPOSAL
PROCEDURES WCH52BDSPOS11004
After deployment or operation, the air bag

D
module and the seat belt pre-tensioner should

be disposed of in the same manner as any other
scrap parts, adhering to local laws and/or legisla-
tion that may be in force except that the follow-
ing points should be carefully noted during dis-
posal
1. The inflator will be quite hot immediately
following deployment, so wait at least 30
minutes to allow it cool before attempting
to handle it.
2. Do not put water or oil on the air bag after
deployment or on the seat belt pre-tensioner
after operation.
3. There may be, adhered to the deployed air
bag module or the operated seat belt pre-
tensioner, material that could irritate the eye
and/or skin, so wear gloves and safety glasses
when handling a deployed air bag module
or operated seat belt pre-tensioner.

52B SRS
/ 124 DEPLOYED AIR BAG MODULE OR OPERATED SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES
CAUTION
If after following these pre-cautions, any
material does get into the eyes or on the
skin, immediately rinse the affected area
with a large amount of clean water. If any
irritation develope, seek medical attention.
4. Tightly seal the air bag module and seat belt
pre-tensioner in a strong vinyl bag for dispos-
al
Symbol Description
Air bag module and seat
A
belt pre-tensioner
B Strong vinyl bag
5. Be sure to always wash your hands after
completeing this operation.
DOIMC52BR07015
T
AF
R
D

CHASSIS ELECTRICAL 54
Content /1
54 CHASSIS ELECTRICAL
BATTERY ................................................................................ 54/8
ON-VEHICLE SERVICE ............................................................... 54/8
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/8
CHECKING BATTERY VOLTAGE AND STATE OF CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/8
RECHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/9
BATTERY RECHARGING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/9
IGNITION SWITCH .................................................................... 54/12

INSPECTION ......................................................................... 54/14
IGNITION SWITCH CONTINUITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/14
KEY REMINDER SWITCH CONTINUITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/14
COMBINATION METER ............................................................... 54/14

SPECIFICATIONS ..................................................................... 54/19
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/19
SEALANT ............................................................................. 54/20
SPECIAL TOOLS ...................................................................... 54/20
ON-VEHICLE SERVICE ...............................................................
T 54/21
54/22
54/22
AF
SPEEDOMETER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/22
INSPECTION CHART FOR TROUBLE SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/25
INSPECTION PROCEDURE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/25
R
HEADLAMP ............................................................................. 54/34

SPECIAL TOOLS ...................................................................... 54/34
D
LOW BEAM SETTING USING SCREEN (INCLINATION PERCENTAGE = 1.2%) . . . . . . . . . . . . 54/36

HIGH BEAM BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/40
LOW BEAM BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/41
POSITION LAMP BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/42
FRONT TURN SIGNAL LAMP BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/42
RELAY INSPECTION ................................................................. 54/43
HEADLAMP RELAY AND ILLUMINATION RELAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/43
SIDE TURN SIGNAL LAMP ........................................................... 54/44

FRONT FOG LAMP .................................................................... 54/47

DIASSEMBLY SERVICE POINT ..................................................... 54/49
RELAY INSPECTION ................................................................. 54/50
FRONT FOG LAMP RELAY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/50
REAR COMBINATION LAMP AND REAR LID LAMP ............................. 54/51


/2 Content
REAR COMBINATION LAMP ......................................................... 54/52

LED ASSY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/52
EXTERIOR LIGHTING .................................................................. 54/52

INSPECTION CHART FOR DIAGNOSIS TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/72
INTERIOR LIGHTING .................................................................. 54/72

BATTERY SAVER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/72
INTERIOR LIGHTING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/73
SYSTEM BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/74
BATTERY SAVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/75
INTERIOR LIGHTS MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/76
INTERIOR LIGHTS BEHAVIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/76
FADE-IN/ FADE-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/76
REMOTE ILLUMINATED ENTRY (APPROACH LAMPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/76
SPECIFICATIONS .................................................................... 54/77
SPECIAL TOOLS ......................................................................

TROUBLESHOOTING ................................................................
T
GENERAL SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/77
54/77
54/77
AF
HIGH MOUNTED STOP LAMP ....................................................... 54/86

R

D
LICENCE PLATE LAMP ASSY ......................................................... 54/89

LICENCE PLATE LAMP REMOVAL ................................................ 54/90
REMOVAL SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/90
SWITCH CENTER ASSEMBLY ........................................................ 54/91

REAR DEFOGGER ...................................................................... 54/93

CLOCK ................................................................................... 54/95

COLUMN SWITCH ..................................................................... 54/97

INSPECTION .......................................................................... 54/98

Content /3
LIGHTING SWITCH, DIMMER / PASSING SWITCH AND TURN-SIGNAL LAMP SWITCH 54/98
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
START/STOP BUTTON ................................................................ 54/99

INTRODUCTION ..................................................................... 54/99
SPECIFICATIONS ..................................................................... 54/100
CHECK AT START STOP BUTTON CONNECTOR ................................ 54/100
WIPER AND WASHER SYSTEM ..................................................... 54/101

FRONT WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/101
Mist wiping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/102
Front wiping (High/Low speed) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/102
Front wiping intermittent control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/102
DWELL-time Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/102
Front wash wiping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/103
Prolongation wiping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/103
Drip wiping: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/103
T
INSPECTION PROCEDURE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION PROCEDURE 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION CHART FOR DIAGNOSIS TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54/106
54/110
54/112
54/113
AF
INSPECTION PROCEDURE FOR FRONT WIPER DIAGNOSIS CODES . . . . . . . . . . . . . . . . . . . . . 54/113
INSPECTION PROCEDURE FOR FRONT AND REAR WASHER DIAGNOSIS CODES . . . . . . . 54/118
HORN .................................................................................... 54/120

HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/120
R
BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/121

SERVICE POINT INSPECTION ...................................................... 54/123
HORN SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/123
D

AUDIO ASSY ........................................................................... 54/124

ANTENNA ............................................................................... 54/126

SPEAKER ................................................................................ 54/128

ALARM SYSTEM ....................................................................... 54/129

ANTI THEFT WARNING SYSTEM (ATWS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/129
ATWS STATE TRANSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/132
PERIMETER ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/133
ATWS STATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/133
ATWS LED INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/133
ATWS ALARM HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/133

/4 Content
ATWS PANIC ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/133

ACOUSTIC ALARM MUTE (CONFIGURABLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/133
DOOR AJAR ACOUSTIC AND/OR VISUAL REMINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/134
ALARM SYSTEM FEATURES ....................................................... 54/134
1. Arming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/134
2. Disarming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/135
3. Automatic re-arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/136
4. Driver door unlock * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/136
5. Vehicle search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/137
6. Door(s)/ tailgate/ hood not closed, remind mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/138
7. Door(s)/ tailgate/ hood/ ignition/ starter protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/139
8. Anti-theft LED indicator for alarm history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/139
9. Panic button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/139
10. Manual override system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/140
SPECIFICATIONS ..................................................................... 54/141
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/146
DIAGNOSTIC FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/146
T
AF
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1319 : Front Left Door . . . . . . . 54/158
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1327 : Front Right Door . . . . . . 54/160
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1335 : Rear Right Door . . . . . . 54/162
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1571 : Rear Left Door . . . . . . . . 54/164
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1331 : Tailgate . . . . . . . . . . . . . . . . 54/166
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1519 : Hood . . . . . . . . . . . . . . . . . . 54/168
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1093 : Key–In Switch . . . . . . . . . 54/170
R
IMMOBILIZER SYSTEM ............................................................... 54/172

INTRODUCTION ..................................................................... 54/172
SPECIFICATION ....................................................................... 54/173
D
SPECIAL TOOLS ...................................................................... 54/174

Wireless And Serial Cable Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/174
CHECK AT KEY RING ANTENNA .................................................. 54/174
SPECIAL FUNCTION MENU ........................................................ 54/176
IMMOBILIZER CODING — 1] KEY ID REGISTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/176
IMMOBILIZER CODING — 2] CLEAR KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/179
INSPECTION CHART FOR TROUBLE SYMPTOMS .............................. 54/181
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS ....................... 54/181
INSPECTION PROCEDURE 1 : Communication With PADT-07 Is Impossible . . . . . . . . . . . . 54/181
INSPECTION PROCEDURES 2 : Engine Does Not Start (Cranking But No Initial Combus- 54/182
tion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION PROCEDURE 3 : Malfunction of The Immobilizer-ECU Power Source and 54/183
Earth Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTE KEYLESS ENTRY SYSTEM (RKE) ......................................... 54/184

TRANSMITTER KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/184
SPECIFICATIONS ..................................................................... 54/186
SPECIAL TOOLS ...................................................................... 54/186

Content /5

HOW TO REPLACE A BATTERY OF THE TRANSMITTER KEY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/199
CENTRAL DOOR LOCKING ........................................................... 54/199

CENTRAL DOOR LOCKING FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/199
Interior button/Key Cylinder on driver door latch Central Lock/Unlock . . . . . . . . . . . . . . . 54/200
Driver Door ONLY Unlock and switching with RC_LOCK+RC_UNLOCK . . . . . . . . . . . . . . . . 54/200
Reverse Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/200
Remote Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/201
Remote Unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/201
Remote Panic Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/201
Vehicle Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/201
Remote command inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/201
T
Speed/Drive away locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto relocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crash unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54/201
54/202
54/202
AF
IGN OFF and key out auto unlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/202
OVERHEATING PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/203
Over heating protection for all door latches and tailgate latch . . . . . . . . . . . . . . . . . . . . . . 54/203
R

SYSTEM BLOCK DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/212
INSPECTION PROCEDURE FOR CENTRAL DOOR LOCKING DIAGNOSIS CODES . . . . . . . . . 54/214
D
CAN BUS SYSTEM ..................................................................... 54/220

CAN COMMUNICATION ........................................................... 54/220
CAN NETWORK TOPOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/220
LED Indication for Self Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/220
CAN SIGNAL MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/221
CAN BUS SPECIFICATION .......................................................... 54/224
ADVANCED BODY CONTROL MODULE (ABCM) ................................ 54/224

ABCM CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/226
ABCM OUTER SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/229
POWER MANAGEMENT ........................................................... 54/230
TROUBLESHOOTING ............................................................... 54/230
SELF DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/230
INSPECTION CHART FOR TROUBLE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/233
DATA LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/234
ACTUATOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/235
TROUBLE SYMPTOM: NO COMMUNICATION WITH PADT-II . . . . . . . . . . . . . . . . . . . . . . . . . . 54/237
TROUBLE SYMPTOM: ALL BCM RELATED FUNCTION ARE NOT WORKING . . . . . . . . . . . . 54/237
CODE: U012987, U010087, U015187, U010187, U015587, U019987 & U016987. . . . . . . 54/238

/6 Content
CODE: U007388 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/239

CODE: U007388 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/239
CODE: U201088 & U201188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/239
CODE: U201088 & U201188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/239
CODE: B131000, B13201C, B133000, B13404B, B135017, B136000 & B137000 . . . . . . . . . 54/239
CODE: B110118 & B110218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/240
CODE: B11512A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/240
CODE: B11B311 , B11B312 & B11B313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/240
CODE: B11B411 , B11B412 & B11B413 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/241
CODE: B11D214 , B11D215 & B11D219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/241
CODE: B11D314 , B11D315 & B11D319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/241
CODE: B11D413 , B11D419, B11D512, B11D513, & B11D519 . . . . . . . . . . . . . . . . . . . . . . . . . . 54/241
CODE: B11D612 , B11D613 & B11D619 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/242
CODE: B113D2A , B115011 & B115012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/242
CODE: B211223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/242
CODE: B169323, B169223, B169313 , B169467 & B169586 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/242
CODE: B169123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54/242
T
AF
R
D

Content /7
NOTE
T
AF
R
D

/8 BATTERY
BATTERY WCH054SPROC11005
ON-VEHICLE SERVICE
VISUAL INSPECTION
1. Inspect the battery terminals and check that
the battery cables and terminal connectors
are clean and tight at all times.
2. Check for cracks or deformation of battery
case / cover, which maybe the result of:
2.1 Excessive tightening of hold down at-
tachment.
2.2 Loose hold down attachment causing
vibrations.
2.3 Mishandling of the battery.
3. Check for evidence if the top label sticker
has been tampered. 'Warranty is VOID' if top
label sticker is tampered.
Symbol Description
T A Top label sticker

4. Inspection after removing the battery from
the vehicle:
AF
4.1 If there is a leak from a crack in the
battery's plastic case / cover, replace the
battery.
4.2 Clean battery terminals with a wire
DOIQC054R11001 brush and replace battery if the termin-
al is damaged.
R
CHECKING BATTERY VOLTAGE AND STATE OF

CHARGE
1. Check the vehicle electrical system. Make
D
sure that the alternator / generator and

voltage regulators are functioning properly.
Charging voltage limits of the alternator
should be between 14.4 volt to 14.8 volt.
2. Inspect the battery voltage and check its
State of Charge (SOC) and determine
whether it is fully charged or need to be re-
charged.
DOIQC054R11002
3. Battery with voltage less than 12.25 volt
must be recharged according to Battery Re-
charging Guide.
Specification Country Reference SG Level

DOM Malaysia and other tropical countries 1.255
BATTERY TESTER
Please use a certified and calibrated Battery
Tester to test the battery.

BATTERY /9
RECHARGING
Battery must be recharged according to Battery
Recharging Guide in the following page
NOTE :
DO NOT remove top label sticker during rechar-
ging because the battery has side ventilation
system and its electrolyte is of high purity con-
tent
CAUTION
(1) Keep all sources of fire away while charging
to avoid possible explosion
(2) Make sure there is sufficient ventilation
during recharging
BATTERY RECHARGING GUIDE
DOIQC054R11003
CAUTION
Battery Recharging Guide MUST be followed
especially on the charging current set up because
higher charging current than recommended may
T cause excessive gassing that block the side

venting system and contribute to 'battery bul-
ging' problem.
AF
Malaysia countries
SG : 1.255 Approximate No. of Hours for Recharging
State of Charge (SOC)
VEHICLE CHARGING CUR- 70% 60% 40% 20%
BATTERY TYPE AH
MODEL RENT (A) 12.10~ 11.95~ 11.65~ 11.35~
R
12.25 V 12.05 V 11.75 V 11.45 V

CR 55D23L 6 60 4 hrs 5 hrs 8 hrs 10 hrs
FOR FULLY DISCHARGED BATTERY, THE RECOMMENDED CHARGING GUIDE
D
Reserve Capacity (RC Rating) Slow Charge

Above 80~125 mins
21 hrs @ 4 amps
55D23L
BATTERY TESTING PROCEDURE
Test step Result Action To take
VISUAL INSPECTION Clean terminals and clamp
NG ⇒
A0 • Remove negative cable, then positive cable. Go to A1
• Check for dirty or corroded connections OK ⇒ Go to A1
Tighten cable clamp at bat-
LOOSE BATTERY TERMINAL CONNECTION NG ⇒
A1 tery terminal
• Check for loose battery terminal connection
OK ⇒ Go to A2
CRACKED BATTERY CASE/COVER NG ⇒ Replace battery
A2 • Remove hold-downs bracket/attachment
• Check for broken/cracked plastic case or cover OK ⇒ Go to A3

/ 10 BATTERY
Test step Result Action To take

OCV
OPEN CIRCUIT VOLTAGE (OCV) TEST LESS Go to A4 and recharge bat-
• Turn headlamps “ON” for 15 seconds THAN tery according to Battery
• Turn headlamps “OFF” for 2 minutes to allow 12.25V Recharging Guide
A3 battery voltage to stabilize NG ⇒
• Disconnect negative terminal OCV AT
• Read Open Circuit Voltage (OCV) LEAST
• OCV reading must be AT LEAST 12.25V Battery OK
12.25V
OK ⇒
BATTERY RECHARGING NG ⇒ Go to A5
• DO NOT remove top label sticker during char-
A4
ging OK ⇒ Go to A5
• Follow Battery Recharging Guide
Dis-
charge
LOAD TEST voltage
• Allow the battery to cool down at least 15 LESS Replace battery
minutes before carrying out load test THAN
A5
Load Test function to the battery
T
• Connect a Load Tester OR Battery Tester with 9.6 Volt
• Set load test current at 1 x battery AH rating

NG ⇒
Dis-
AF
(No need to do if Battery Tester does not have charge
“set load test current function”) voltage
• Load test time is 5 second AT Battery OK
• Discharge voltage must be at least 9.6 V LEAST
9.6 Volt
OK ⇒
R
• Use suitable or appropriate battery testing equipment which is able to check OCV (open circuit
voltage), CCA (cold cranking ampere) such as battery tester, load tester and battery charger.
• Use only equipment recommended by Proton.
D
NOTE :
Battery Charger shall have a selectable charging current function i.e. 1 Amp ~ 15Amp to ensure low
current charging can be carried out to the battery.

BATTERY / 11
BATTERY “DOS” AND “DON'TS”

“DOS” “DON'TS
1. To install the battery, please connect positive 1. Do not make any direct contact between pos-
(+ve) cable first than followed by negative (- itive (+ve) and negative (-ve) terminals of the
ve) cable. battery.
2. To remove the battery, please disconnect 2. Do not jump start the battery because it may
negative (-ve) cable first than followed by create internal short circuit that may reduce
positive (+ve) cable. its life span.
3. Do not open ventilation caps because the
battery has pure electrolyte content and
higher active material that is very sensitive to
contaminants.
4. Do not leave any electrical accessories and door
open for long period of time without the en-
gine running because it will discharge the
battery.
5. Do not force down the battery terminal, al-
ways use the right tool to install and remove
cable terminals.
NOTE :
T
(1) For long storage of vehicle i.e. storage yard, showroom etc. please disconnect negative (-ve)
terminal of battery.
AF
(2) For long storage purposes, battery shall be recharged according to Battery Recharging Guide
every three months OR whenever battery SOC is LESS THAN 12.25 V, whichever comes first.
(3) Before delivering new vehicle to customer, battery SOC shall be checked and any batteries with
voltage LESS THAN 12.25 V shall be recharged according to Battery Recharging Guide.
BATTERY TESTER
Please use a certified and calibrated Battery
R
Tester to test the battery.

D

/ 12 IGNITION SWITCH
IGNITION SWITCH WCH054SASSY11005
T
AF
R
DOIQC054R11053
D
CAUTION : SRS
Air bag module and clock spring removal (Refer to GROUP 52B - SRS Service Precautions Air Bag
Module and Clock spring).
Column switch segment removal steps Key reminder switch removal steps
1. Panel assy lower driver side 7. Column switch
2. Column cover upper 8. Ignition key ring
3. Column cover lower 9. Key lock cylinder
4. Air bag module/ Horn pad 10. Ignition switch
5. Steering wheel 11. Key reminder switch
6. Clock spring
7. Column switch
T1 : 3.4~4.5 Kgf.m

IGNITION SWITCH / 13
KEY LOCK CYLINDER REMOVAL

1. Insert the key in the steering lock cylinder
and turn to the “ACC” position.
2. By using a cross-tip (+) screwdriver or a simil-
ar tool, push the lock pin of the key lock cyl-
inder inward and then pull the key lock cyl-
inder.
Symbol Description
Cross-tip (+) screwdriver or a
DOINC054R09001 A
similar tool

KEY LOCK CYLINDER INSTALLATION
1. Insert the key in the key lock cylinder and
turn to the “ACC” position.
T
2. Push the lock pin and make sure the lock pin
in free position (in or out).
3. Make sure the lock pin parallel to the look
pin hole at the cylinder housing and slot in
AF
the steering lock cylinder.
4. Make sure the lock pin is looked.
Symbol Description
A Lock pin
B Look pin hole
R
D
DOINC054R09002

/ 14 COMBINATION METER
INSPECTION
IGNITION SWITCH CONTINUITY CHECK
1. Remove the column cover lower and upper.
2. Disconnect the wiring connector from the
ignition switch.
3. Operate the switch and check the continuity
between the terminals.
Ignition Terminal No. Continuity Check

key posi-
tion
DOINC054R09003 LOCK —
ACC Terminal No.2 connected → to
Terminal No.5
Terminal No.2 connected → to
IG1
Terminal No.5 and 1
Terminal No.2 connected → to
IG2
Terminal No.3
T
START Terminal No.2 connected → to
Terminal No.6
KEY REMINDER SWITCH CONTINUITY CHECK
AF
1. Disconnect the key reminder switch connect-
or with the switch installed on the vehicle
and then check continuity.
Ignition Terminal No. Continuity Check

key
R
Removed Terminal No.2 connected → to

Terminal No.5
Inserted —
D
DOINC054R09046
COMBINATION METER WCH054GINFO11001
GENERAL INFORMATION
There are warning and indicator lamps in the combination meter as shown in the figure.

COMBINATION METER / 15
T
AF
DOIQC054R11004
R
TELL TALE COL-

No FUNCTION IN PUT / OUT PUT
OUR
1 LEFT TURN GREEN CAN BUS (BCM)
D
2 RIGHT TURN GREEN CAN BUS (BCM)

3 AIR BAG RED CAN BUS (ACU)
INPUT :
- EXTERNAL SWITCH
4 HIGH BEAM BLUE OUTPUT :
1. GROUND
2. EXTERNAL SWITCH
5 ABS YELLOW CAN BUS (ABS)
6 SEATBELT RED EXTERNAL SWITCH
7 BATTERY RED EXTERNAL SWITCH
8 OIL PRESSURE RED EXTERNAL SWITCH
9 CHECK ENGINE YELLOW EXTERNAL SWITCH
10 PARKING BRAKE / EBD RED EXTERNAL SWITCH & CAN BUS (ABS)
STANBY YELLOW
11 AUTOCRUISE EXTERNAL SWITCH
ACTIVE GREEN
12 REAR DEFOGGER YELLOW CAN BUS (BCM)
13 REAR FOG YELLOW CAN BUS (BCM)

TELL TALE COL-

No FUNCTION IN PUT / OUT PUT
OUR
14 FRONT FOG GREEN CAN BUS (BCM)
15 LOW FUEL YELLOW FUEL SENDER
16 POSITION LAMP GREEN EXTERNAL SWITCH
17 ESC (ACTIVE / FAIL) YELLOW CAN BUS (ESC)
18 ESC - OFF YELLOW CAN BUS (ESC)
19 TRANSMISSION DEFAULT RED CAN BUS (TCU)
20 SAT (STEPPED AUTOMATIC) GREEN CAN (TCU)
The BCM controls the buzzer or sends CAN message for audible Warning/ Acknowledgment (Ack) to
the combination meter.
There are 10 types of Warning/ Ack associated with BCM as follows:
• ICU (Internal Control Unit) buzzer warning (Via CAN).
1. Any Door Ajar Warning
2. Key In ignition lock cylinder warning
3. Light Left-On warnings
• BCM buzzer acoustic Ack (via Buzzer).
1.
2.
Remote Panic Ack
Remote Lock Ack
T
AF
3. Remote Unlock Ack
4. Remote Trunk Release Ack
5. Remote Vehicle Search Ack
6. Enter Key Learning Mode Ack
7. New Key Learnt Ack
R
D

SYSTEM BLOCK DIAGRAM
T
AF
R
DOINC054R09103
• Any Door Ajar Warning

If there is any door/tailgate/hood ajar
D
1. BCM will transmits 4 doors, tailgate and hood ajar status on CAN BUS to combination meters IF
BCM is in ACTIVE State.
2. Combination meters will implement the buzzer chime by checking IGN status.
3. BCM will remain in ACTIVE State for at least 30s after IGN OFF.
• Key In Ignition Lock Cylinder Warning
BCM will send key in warning signal to CAN Bus so that combination meters can trigger buzzer chime
in following conditions.
1. Ignition switch : OFF.
2. key is inserted in ignition lock key cylinder.
3. driver door is ajar/ open.

• Remote Keyless Entry (RKE) Transmitter Key's Battery Low Warning
DOINW005R09019
If the RKE transmitter key battery is weak, the RKE Battery Low indicator will be illuminated for 8
seconds (refer to GRP 054 RKE System Section for details).
• Light Left–On Warning
If head lamp or position lamps is turned ON and detected by BCM via feedback line and if these lamps
activation is not triggered by the BCM automatic functions as follows:
1. Remote transmitter unlock or
2. Vehicle search or
3. Home safe light request
T
AF
and IF the
1. Ignition is in OFF position
2. Key is not in ignition key lock cylinder
3. Driver door is open
BCM will send the Light Left-On warning signal via the CAN BUS so that the Combination Meters can
trigger the buzzer chime.
R
Buzzer Chime Function Specifications

The buzzer chime function specifications are listed in the table below.
The buzzer is located inside the combination meter and produces a chiming sound whenever the below
D
conditions are met.
Function Buzzer Function

Activated • Coolant temperature is more than 121 °C (249.8 °F).
Temperature Warning
De-Activated • Coolant temperature <118 °C (244.4 °F).
• Vehicle speed is more than 7 km/ h and if any door is
Door Ajar Warning Activated opened or ajar.
Door ajar signal provided by BCM
• Driver's seatbelt is unfastened.
Seat Belt Unfastened
Activated • Vehicle speed is more than 7 km/ h.
Warning
• If any door is opened/ ajar.
• IGN switch: OFF.
Key Left In Warning Activated • Key is in Ignition key cylinder.
• Driver door is opened/ ajar.
• Headlamp: ON.
Activated • Key is NOT in Ignition key cylinder.
Light Left - On Warning • Driver door is opened/ ajar.
De-Activated Home safe light: ON

TEMPERATURE LEVEL:
Temperature level display Indication bar
118-130 °C (244.4-266 °F) 8 BAR
114-117 °C (237.2-242.6 °F) 7 BAR
110-113 °C (230-235.4 °F) 6 BAR
106-109 °C (222.8-228.2 °F) 5 BAR
76-105 °C (168.8-221 °F) 4 BAR (NORMAL)
64-75 °C (147.2-167 °F) 3 BAR
51-63 °C (123.8-145.4 °F) 2 BAR
40-50 °C (104-122 °F) 1 BAR
FUEL LEVEL:
Fuel level display Fuel volume (litre) Indication bar & Warning lamp
8 (FULL TANK) 42 ~ 47 Liter 7 BAR
T
7/8 37 ~ 41 Liter 7 BAR
6/8 32 ~ 36 Liter 6 BAR
5/8 27 ~ 31 Liter 5 BAR
AF
4/8 (HALF TANK) 22 ~ 26 Liter 4 BAR
3/8 17 ~ 21 Liter 3 BAR
2/8 12 ~ 16 Liter 2 BAR
1/8 9 ~ 11 Liter 1 BAR
WARNING 8 Liter Last bar indicator blink at 1 Hz and
R
fuel warning lamp always ‘ON’

EMPTY 5.0 Liter Fuel warning indicator blink at 1
Hz
D
FUEL GAUGE:
+7Ω
Float point F 10 Ω
–1Ω
Fuel gauge unit resistance Ω
+ 10 Ω
Float point E 265 Ω
–8Ω
A (Float
156 mm (6.14 in) ±2 mm (0.079 in)
point F)
Fuel gauge unit float height
B (Float
36 mm (1.42 in) ± 2 mm (0.079 in)
point E)
SPEEDOMETER INDICATION TOLERANCE:
Speed (km/h) 20 40 60 80 100 120 140 160 180 200 220 240
+4.0 +4.0 +4.5 +5.5 +6.5 +7.5 +8.5 +9.5 +10.5 +11.5 +12.5 +13.0
Tolerance (km/h)
0 0 0 +0.5 +1.0 +1.5 +2.0 +2.5 +3.0 +3.5 +4.0 +4.5

TACHOMETER INDICATION TOLERANCE:

Nominal (rpm) Voltage / Temp 1000 2000 3000 4000 5000 6000 7000 8000
Voltage :13.5v +100 +100 +100 +100 +100 +100
- -
Temp : Room Temp –100 –100 –200 –300 –375 –450
Tolerance (rpm) Voltage :10 ~ 15v +150 +175 +175 +200 +200 +200
Temp : - 30- ~ - 80- - -
- °C (NaN- ~ NaN- -150 -175 -275 -400 -475 -550
NaN °F)
SEALANT
Items Specified sealant Remark
Engine coolant temperature 3M Adhesive nut locking No. 4171 or
Drying
gauge unit threaded portion equivalent
EZT0038
T Set of Diagnostic : Pro- For vehicle diagnos-

ton Advance Diagnostic is, ECU flashing and
AF
Tool-07 troubleshooting.
DOIIC11AR07018
Removal of front
bumper mounting
clips, combination
meter lower cover,
R
MB990784 Ornament remover door mirror and

housing cover,
quater assy trim cap
DOIHC051R04017
and center panel
D
assy.

T
AF
R
DOIQC054R11005

• Adjust steering at lower position.
D
Combination meter removal steps

1. Meter combination cover
2. Meter combination

METER COMBINATION REMOVAL

1. Use the special tool to pry out the meter
combination lower cover.
DOIQC054R12033
SPEEDOMETER INSPECTION
1. Adjust the pressure of the tyres to the spe-
cified level. (Refer to GROUP 031 – Wheel
and tyre.)
2. Set the vehicle onto a speedometer tester
T and use wheel chocks to hold the rear

wheels.
AF
Symbol Description
A Chocks
DOIKC054R03030
3. To prevent the front wheel from moving side

to side, attach tension bars to the tie-down
hook, and secure both ends to anchor plates.
R
4. To prevent the vehicles from starting, attach

a chain or wire to the rear retraction hook,
and make sure the end of the chain or wire
is secured firmly.
D
5. Check if the speedometer indicator range is

within the standard values.
Symbol Description
A Tie-down hook
DOIKC054R03031 B Tension bar
C Front
D Anchor plate
CAUTION
Do not operate the clutch suddenly. Do not
increase / decrease speed rapidly while
testing.

TACHOMETER INSPECTION
Symbol Description
A Wireless method
B Cable method
1. Start the engine prior to connect the PADT-
II (VCI).
2. Connect PADT-II (VCI) to diagnostic connect-
or.
3. Switch “ON” the VCI and select the commu-
nication method by using trigger button. By
default, it will choose wireless method.
4. In PADT-II software select vehicle model then
engine system followed by EMS 700.
5. The system will display system information
then click “OK” button.
6. In dynamic display table, observe the ENGINE
SPEED value.
T
AF
DOIQC054R12032
FUEL GAUGE HARNESS INSPECTION

HARNESS SIDE:
R
Symbol Description
A Test lamp 12V-3.4W
D
1 Fuel gauge (Meter)

2 Fuel pump (+)
3 —
4 Fuel pump (-)
5 Fuel gauge (Ground)
DOIQC054R11010

Remove the fuel gauge
1 — go to state 2
unit connector
Key at start or ignition pos- Test lamp illuminate Replace the pump
ition. Use the special tool
2 to connect a test lamp12
V) to the harness connector Test lamp not illuminate Repair the harness
(Pin no. 2 and no. 4).


When the ignition switch Test lamp illuminate Replace the fuel gauge unit
is turned to “ON” position.
Use the special tool to
3
connect a test lamp12 V) Test lamp not illuminate Repair the harness
to the harness connector
(Pin no. 1 and no. 5).
FUEL GAUGE UNIT INSPECTION
Remove the fuel gauge unit from the fuel tank.
(Refer to GROUP 13 – fuel tank.)
Fuel gauge unit resistance :
1. Check that resistance value between the fuel
gauge terminal and earth terminal is at
standard value when fuel gauge unit float
is at point F (highest) and point E (lowest).
Standard value:
Point F +7Ω
10.0 Ω
T
(highest) –1Ω
Point E + 10 Ω
289 Ω
(lowest) –8Ω
AF
2. Check that resistance value changes smoothly
when float moves slowly between point F
(highest) point E (lowest).
Connector no. Description

1 Fuel gauge (Meter)
R
2 Fuel pump (+)

3 —
4 Fuel pump (–)
D
5 Fuel gauge (Ground)
DOIQC054R11011
Fuel gauge unit float height :

Move float and measure the height A at point F
(highest) and B at point E (lowest) with float arm
touching stopper.
Symbol Description
C Point F (highest)
D Point E (lowest)
Standard value:
A : 142.3 mm (5.6 in) ±2 mm (0.079 in)
B : 0 mm (0 in) ± 2 mm (0.079 in)
DOIQC054R11012


Inspection proced-
Trouble symptom Reference page
ure no.
Door ajar warning not working (Instrument Panel Buzzer
1 WCH054TSHOT183
Chime not audible)
Key in Ignition Lock Cylinder warning not working (Instru-
2 WCH054TSHOT184
ment Panel Buzzer Chime not audible)
Light left on warning not working (Instrument Panel Buzzer
3 WCH054TSHOT185
Chime not audible)
INSPECTION PROCEDURE 1 WCH054TSHOT11002
Door ajar warning not working (Instrument Panel Buzzer Chime not audible)
Probable Cause
• Malfunction of the Contact Switch
The cause may be a faulty contact switch, or no power
to the Combination Meter and/or the BCM, or malfunc- • Malfunction of the wiring harness or con-
nectors
T
tion of the wiring harness, or malfunction of the
Combination Meter or the BCM • Malfunction of the Combination Meter
• Malfunction of BCM
AF
State Instruction Condition Next State
Refer Inspection
Chart for Dia-
Are any of the BCM's Diagnosis Trouble Codes dis- YES gnosis Trouble
1 played? Codes on page
R
WCH054TSHOT129
NO GO TO 2
Does the Door Ajar LED Indicator warning on the OK GO TO 7
D
2 Combination Meter work properly when one or more

doors are opened? NG GO TO 3
Check Fuses: OK GO TO 4
• No. 19 (20 A) Memory (IP) in the Panel Fuse Box
3 Replace the Fuse
• No. 14 (10 A) Ignition 1- BCM in the Panel Fuse Box NG
and GO TO 4
• No. 18 (15 A) Door Lock Power in the Panel Fuse Box


Disconnect connectors C-16 and C-17 and check at the OK GO TO 5
Harness Side:
(a) Check Voltage between connector C-17 Pin No. 7
(Door Lock Power) and
Repair the af-

4 fected connect-
NG
ors and/or the
wiring harness
DOINC054R09135
T
• C-17 Pin No. 8 (Ground Power) and
• C-16 Pin No. 5 (Ground Signal)
OK: System Voltage
AF
(b) Check Voltage between connector C-15 Pin No. 33
(Ignition 1- BCM) and
OK: System Voltage
Check all the connectors of the Interior Lighting Switch OK GO TO 6

R
and BCM for proper connection and mating

• D-09 Combination Meter
5 Repair the af-
• C-15 BCM NG fected connect-
D
• C-16 BCM ors

• C-17 BCM
• Disconnect Combination Meter connector D-09 and OK GO TO 7

measure at the harness side:
Repair or re-
• Voltage between Pin No. 1 (Battery Main) and Pin
6 place the af-
No. 4 (Ground)
NG fected connect-
OK: System voltage ors and/or the
Ignition: OFF wiring harness


Disconnect the BCM Connectors C-15 and Meter Com- OK GO TO 8
bination (ICU) Connector D- 09 and check the Continuity
of the CAN Bus Wire (Twisted Wire) at the Harness Side:
(a) Check Continuity between connectors C-15 Pin No.
30 (CAN High BCM) and
• D-09 Pin No. 21 (CAN High ICU)
OK: Continuity Replace CAN Bus
7
(b) Check Continuity between connectors C-15 Pin No. NG Wire (Twisted
40 (CAN Low BCM) and Wire)
• D-09 Pin No. 20 (CAN Low ICU)

OK: Continuity
(refer to Electrical Wiring: Circuit Diagrams-Alarm
System MODULE 4.3, GROUP 14)
Check the harness wire between the fusible link no. 2 OK GO TO 9

8 and BCM NG Repair/Replace
9
switch one by one:
T
Check the door switch by pressing the door contact OK GO TO 10
AF
Observe the door ajar signal in the Combination Meter NG Replace
Check the following connectors: OK GO TO 11
10 • C-02, C-03, C-13, C-15, C-16, C-17

NG Repair/Replace
• E-01, E-04, E-06, E-09
R
Check the harness wire between the door switch and OK GO TO 12

11 BCM, C-15 NG Repair
Ignition Key cylinder switch continuity check (refer to OK GO TO 13
D
12 GRP 54–IGNITION SWITCH) NG Replace
Check the trouble symptom OK GO TO 16

13
NG GO TO 14
Check the harness wire OK GO TO 15
• Between ignition key cylinder, D-16 and BCM, C-16
14
• Between ignition key cylinder, D-16 and earth. NG Repair
Replace the Combination Meter and check the trouble OK GO TO 16

15
symptom NG Replace BCM
Refer Inspection
Chart for Dia-
16 Codes on page
played?
WCH054TSHOT129
NO STOP

Key in Ignition Lock Cylinder warning not working (Instrument Panel Buzzer Chime not audible)
Probable Cause
• Malfunction of the Contact Switch
to the Combination Meter and/or the BCM, or malfunc- • Malfunction of the wiring harness or
tion of the wiring harness, or malfunction of the Combin- connector
ation Meter or the BCM • Malfunction of the Combination Meter

Refer Inspection Chart
Are any of the BCM's Diagnosis Trouble Codes for Diagnosis Trouble
YES
1 displayed? Codes on page
WCH054TSHOT129
NO GO TO 2
2 Combination Meter work properly when one or
more doors are opened?
Check Fuses:
T NG
OK
GO TO 3
GO TO 4
AF
• No. 14 (10 A) Ignition 1 - BCM in the Panel Fuse
3 Replace the Fuse and
Box NG
GO TO 4
• No. 18 (15 A) Door Lock Power in the Panel Fuse
Box
R
D


Disconnect connectors C-16 and C-17 and check OK GO TO 5
at the Harness Side:
(a) Check Voltage between connector C-17 Pin
No. 7 (Door Lock Power) and
4 Repair the affected

NG connectors and/or the
wiring harness
DOINC054R09135
T
OK: System Voltage
AF
(b) Check Voltage between connector C-15 Pin
No. 33 (Ignition 1- BCM) and
OK: System Voltage
Check all the connectors of the Interior Lighting OK GO TO 6

R
Switch and BCM for proper connection and mating

5 • C-15 BCM Repair the affected
NG
D
connectors
• C-16 BCM
• C-17 BCM
• Disconnect Combination Meter connector D-09 OK GO TO 7

and measure at the harness side:
• Voltage between Pin No. 1 (Battery Main) and Repair or replace the
6 Pin No. 4 (Ground) affected connectors
NG
OK: System voltage and/or the wiring har-
ness
Ignition: OFF


Disconnect the BCM Connectors C-15 and Meter OK GO TO 8
Combination (ICU) Connector D- 09 and check the
Continuity of the CAN Bus Wire (Twisted Wire) at
the Harness Side:
(a) Check Continuity between connectors C-15 Pin
No. 30 (CAN High BCM) and
7 OK: Continuity Replace CAN Bus Wire
NG
(b) Check Continuity between connectors C-15 Pin (Twisted Wire)
No. 40 (CAN Low BCM) and
OK: Continuity
Check the harness wire between the fusible link OK GO TO 9

8 no. 2 and BCM
T
Check the door switch by pressing the door con-
NG
OK
Repair/Replace
GO TO 10
AF
tact switch one by one:
9
Observe the door ajar signal in the Combination NG Replace
Meter
10 • C-02, C-03, C-13, C-15, C-16, C-17

R
NG Repair/Replace
• E-01, E-04, E-06, E-09
Check the harness wire between the door switch OK GO TO 12

11 and BCM, C-15
D
NG Repair
Ignition Key cylinder switch continuity check (refer OK GO TO 13
12 to GRP 54–IGNITION SWITCH) NG Replace

13
NG GO TO 14
• Between ignition key cylinder, D-16 and BCM,
14 C-16
NG Repair
• Between ignition key cylinder, D-16 and earth.
Replace the Combination Meter and check the OK GO TO 16

15
trouble symptom NG Replace BCM
for Diagnosis Trouble
Are any of the BCM's Diagnosis Trouble Codes YES
16 Codes on page
displayed? WCH054TSHOT129
NO STOP

Light left on warning not working (Instrument Panel Buzzer Chime not audible)
Probable Cause
• Malfunction of the contact switch
to the Combination Meter and/or the BCM, or malfunc- • Malfunction of the wiring harness or
tion of the wiring harness, or malfunction of the Combin- connector
ation Meter or the BCM • Malfunction of the Combination Meter

YES
WCH054TSHOT129
NO GO TO 2
2 Combination Meter work properly when one or
more doors are opened?
Check Fuses:
T NG
OK
GO TO 3
GO TO 4
AF
Box NG
GO TO 4
Box
R
D


Disconnect connectors C-16 and C-17 and check at OK GO TO 5
the Harness Side:
(a) Check Voltage between connector C-17 Pin No.
7 (Door Lock Power) and

wiring harness
DOINC054R09135
T
OK: System Voltage
AF
(b) Check Voltage between connector C-15 Pin No.
33 (Ignition 1- BCM) and
OK: System Voltage

R

• D-14 Headlamp Switch
5
D
Repair the affected

• C-15 BCM NG
connectors
• C-16 BCM
• C-17 BCM
• Disconnect Combination Meter connector D-09 OK GO TO 7

and measure at the harness side:
• Voltage between Pin No. 1 (Battery Main) and Repair or replace the
6 Pin No. 4 (Ground) affected connectors
NG
OK: System voltage and/or the wiring har-
ness
Ignition: OFF


Disconnect the BCM Connectors C-15 and Meter OK GO TO 8
Combination (ICU) Connector D- 09 and check the
Continuity of the CAN Bus Wire (Twisted Wire) at
the Harness Side:
(a) Check Continuity between connectors C-15 Pin
No. 30 (CAN High BCM) and
7 OK: Continuity Replace CAN Bus Wire
NG
(b) Check Continuity between connectors C-15 Pin (Twisted Wire)
No. 40 (CAN Low BCM) and
OK: Continuity

8 no. 2 and BCM
T
Check the door switch by pressing the door contact
NG
OK
Repair/Replace
GO TO 10
AF
switch one by one:
9
Observe the door ajar signal in the Combination NG Repair/Replace
Meter
10 • C-02, C-03, C-13, C-15, C-16, C-17

R
NG Repair/Replace
• E-01, E-04, E-06, E-09

11 and BCM, C-15
D
NG Repair/Replace
Ignition Key cylinder switch continuity check (refer OK GO TO 13
12 to GRP 54–IGNITION SWITCH) NG Repair/Replace

13
NG GO TO 14
14 C-16
NG Repair
Replace the Combination Meter and check the OK GO TO 16

15
trouble symptom NG Replace BCM
16 Codes on page
NO STOP

/ 34 HEADLAMP
HEADLAMP WCH054STOOL11002
SPECIAL TOOLS
Set of Diagnostic : Pro- For vehicle diagnos-

EZT0038 ton Advance Diagnostic is, ECU flashing and
DOIIC11AR07018
Removal of front
bumper mounting
clips, combination
meter lower cover,
MB990784 Ornament remover door mirror and
housing cover,
quarter assy trim
DOIHC051R04017
cap and center
T
panel assy.
AF
R
D

HEADLAMP / 35
T
AF
R
DOIQC054R11006

• Front bumper removal (Refer to GROUP 051– Front bumper).
D
Removal steps
1. Center body mounting bracket
2. Headlamp
T1 : 0.5 kgm (5 Nm, 3.62 ft.lbs) ± 0.075 kgm (0.75 Nm, 0.54 ft.lbs)
T2 : 0.77 kgm (7.7 Nm, 5.57 ft.lbs)

/ 36 HEADLAMP
LOW BEAM SETTING USING SCREEN

(INCLINATION PERCENTAGE = 1.2%)
1. Inflate the tyres to the specified pressures
and there should be no other than the driver
or substitute weight of approximately 75 kg
(750 N, 165.38 lbs) placed in driver's position.
2. Park a car on flat surface floor with 3 m (9.84
ft) distance from flat vertical screen.
Symbol Description
DOIQC054R11007
A Low beam
B Flat vertical screen
C Line (The line is 3 m (9.84 ft)
distance between low beam
and screen)
3. The 3 m (9.84 ft) distance is measured from
center point of each low beam to the flat
vertical screen.
T Symbol
A
Description
Low beam center point
AF
B Flat vertical screen
NOTE:
The car must be parked in straight position
(perpendicular to the screen 'B') and all tyres
are aligned.
R
DOIQC054R11008
4. Measure height of low beam from flat sur-

face floor using measuring tape.
Example:
D
Low beam height (B) = 73 cm (28.74 in)
Symbol Description
A Measuring tape
B Low beam height
(73 cm (28.74 in))
C Ruler
NOTE:
DOIQC054R11009 Actual low beam height is depends on vari-
ants of car used and suspension settings (if
any), which are need to be measured as well.

HEADLAMP / 37
5. Draw a first horizontal line (Line 1) on the

screen.
The line 1 height must be equal to low beam
height. Point E is the low beam center point
with 3 m (9.84 ft) horizontal distance as
Example:
Low beam height (B) = 73 cm (28.74 in)
Symbol Description
Line 1 First horizontal line
E Point E
DOIQC054R11015
B Low beam height
(73 cm (28.74 in))
6. To get second horizontal line (Line 2), please
use this formula.
Example:
If the car distance to screen = 3 m (9.84 ft).
Formula:
T Tan 0.68°
t
=
=
t / 3m
Tan 0.68° x 3m
AF
= 35.6 mm (1.4 in)
Symbol Description
t Height (35.6 mm (1.4 in))
DOIQC054R11016
7. Draw a second horizontal line (Line 2), 35.6

mm (1.4 in) below the first horizontal line
R
(Line 1).
Symbol Description
D
Line 2 Second horizontal line

E Point E
t Height (35.6 mm (1.4 in))
DOIQC054R11017

/ 38 HEADLAMP
8. To get point F, draw a Vertical line across

point E as shown in the illustration.
Symbol Description
Line 2 Second horizontal line
V Vertical line
E Point E
F Point F
DOIQC054R11018
9. Draw 15° slopping line from point F.
Symbol Description
SL Slopping line
E Point E
F Point F
T 10. Repeat all related procedure above for an-

other side of low beam.
AF
DOIQC054R11019
11. Swith “ON” low beam light and check if the

beam shines in 15° slopping to point F.
R
Symbol Description
F Point F
BSA Beam shinning area
D
DOIQC054R11020
If the low beam shinning is not aim to point

F, adjust the headlamp until both low beams
aim at both point F (RHS/LHS).
Vertical direction adjustment

UP (U) Anti clockwise
DOWN (D) Clockwise
DOIQC054R11021

HEADLAMP / 39
Horizontal direction adjustment (Headlamp

RHS)
IN (R) Anti clockwise
OUT (L) Clockwise
NOTE:
To adjust the aiming, use screw driver to
twist the adjuster by folowing the instruc-
tion on the headlamp symbol.
DOIQC054R11022
Horizontal direction adjustment (LHS)

IN (R) Anti clockwise
OUT (L) Clockwise
T HEADLAMP REMOVAL
1. Remove the front bumper.
AF
DOIQC054R11023
2. Remove 2 pieces of bolts from center body

mounting bracket.
R
Symbol Description
A Center body mounting
bracket
D
DOIQC054R11026
3. Disconnect the headlamp connector (2

pieces).
Symbol Description
A Headlamp connector
B Front turn signal lamp con-
nector
DOIQC054R11027

/ 40 HEADLAMP
HIGH BEAM BULB REPLACEMENT

1. Remove the rubber cap..
Symbol Description
A Rubber cap
B Flange
NOTE:
When installing the rubber cap, make sure
the rubber cap flange always on the top
position.
DOIQC054R11031
2. Remove the bulb together with the insula-

tion housing.
Symbol Description
A Bulb
B Insulation housing
T
AF
DOIQC054R11032
3. Remove the bulb from the insulation housing

and replace it with the new one.
R
Symbol Description
C Insulation housing
D Bulb
D
CAUTION
Do not touch the surface of the bulb with
hands or dirty glove. If the surface does be-
come dirty, clean it with alcohol or thinner,
and let it dry thoroughly before installation.
DOIQC054R11033
4. Install the new bulb with the insulation

housing to the HB reflector - sound should
appear.
Symbol Description
E Insulation housing
F HB reflector
DOIQC054R11034

HEADLAMP / 41
LOW BEAM BULB REPLACEMENT

1. Remove the rubber cap.
Symbol Description
A Rubber cap
B Flange
NOTE:
When installing the rubber cap, make sure
the rubber cap flange always on the top
position.
DOIQC054R11028
2. Remove the insulation housing properly.
Symbol Description
A Insulation housing
T
AF
DOIQC054R11035
3. Unlock the bulb retainer spring properly.
Symbol Description
R
A Bulb retainer spring

D
DOIQC054R11029
4. Remove the bulb.
Symbol Description
B Bulb
CAUTION
hands or dirty glove. If the surface does be-
come dirty, clean it with alcohol or thinner,
and let it dry thoroughly before installation.
DOIQC054R11030

/ 42 HEADLAMP
POSITION LAMP BULB REPLACEMENT

1. Remove the rubber cap.
Symbol Description
A Rubber cap
DOIQC054R12018
2. Pull out the bulb holder’s handle and remove

the bulb.
Symbol Description
B Bulb holder’s handle.
T
AF
DOIQC054R12017
FRONT TURN SIGNAL LAMP BULB REPLACEMENT

Turn the front turn signal lamp (anti-clockwise)
together with the socket and then remove the
R
bulb.
Symbol Description
D
A Front turn signal lamp
DOIQC054R12019

HEADLAMP / 43
RELAY INSPECTION WCH054SPROC11011
HEADLAMP RELAY AND ILLUMINATION RELAY

CHECK
1. Remove the headlamp relay from the engine
fuse box (UEC).
Symbol Description
A Headlamp relay
2. Check terminal continuity.
Battery Terminal No. Continu- Remark

voltage ity Check
Power is Terminal No.1(30)
Continu-
supplied connect → Terminal
ity
No.4(87)
Terminal No.1(30)
No con-
connect → Terminal
Power is tinuity
No.4(87)
not sup-
Terminal No.2(86)
T
plied Continu-
connect → Terminal
ity
No.3(85)
AF
DOIQC054R12041
R
D

/ 44 SIDE TURN SIGNAL LAMP
SIDE TURN SIGNAL LAMP WCH054SASSY11008
T
AF
R
DOIQC054R11013
D
Removal steps
1. Mirror lens (Refer to Group 051 - Door mirror assy)
2. Housing cover (Refer to Group 051 - Door mirror assy)
3. Side turn signal lamp assy

SIDE TURN SIGNAL LAMP / 45

WCH054SPROC11012
SIDE TURN SIGNAL LAMP REMOVAL

1. For complete removal and installation pro-
cedures for the Door Mirror Assy, please refer
Chassis Manual, Group 051.
2. Unhook all 4 clamps to release the Housing
Cover.
Symbol Description
A Clamp
B Actuator Door Mirror
DOIKC054R09009
T 3. Remove the housing cover.
Symbol Description
AF
A Housing cover
B Side Turn Signal Sub Assy
R
DOIKC054R09010
D
4. Disconnect the Side Turn Signal Lamp Assy

connector.
Symbol Description
A Connector
DOIKC054R09011

/ 46 SIDE TURN SIGNAL LAMP
5. Remove 2 pieces of tapping screw of the Side

Turn Signal Lamp Assy from the inside of the
Door Mirror Assy.
Symbol Description
A Tapping screw
DOIKC054R09012
6. Remove another 2 pieces of tapping screw

of the Side Turn Signal Lamp Assy from the
outside of the Door Mirror Assy.
Symbol Description
A Tapping screw
T
AF
DOIKC054R09013
7. Pull up the outer edge of the Side Turn Sig-

nal Lamp slightly to release the Side Turn
Signal Lamp from the slot.
R
Symbol Description
A Side Turn Signal Sub Assy
D
DOIKC054R09014
8. Remove the Side Turn Signal Lamp Assy

properly.
Symbol Description
A Side Turn Signal Sub Assy
DOIKC054R09015

FRONT FOG LAMP / 47
FRONT FOG LAMP WCH054SASSY11009
T
AF
R
DOIQC054R11014
D

• Front bumper removal and installation (Refer to GROUP 051 — Front bumper).
Removal step
1. Fog lamp cover
2. Front fog lamp assy

/ 48 FRONT FOG LAMP
T
AF
R
DOINC054R09019
Removal steps
1. Bulb socket holder
D
2. Bulb
3. Front fog lamp
4. Bracket

FRONT FOG LAMP / 49
DIASSEMBLY SERVICE POINT

WCH054SPROC11013
FRONT FOG LAMP BULB REMOVAL

1. Disconnect the fog lamp connector.
Symbol Description
A Connector harness
DOIQC054R11024
2. Turn the bulb socket holder assy (anti-clock-

wise) for removal and replace with a new
one.
Symbol Description
B Bulb socket holder
C Bulb
T CAUTION
AF
bare hands or dirty gloves. If the surface
does become dirty, let the bulb cool down
DOIQC054R11025
and then clean it with alcohol or thinner and
let it dry thoroughly before installation.
R
D

/ 50 FRONT FOG LAMP
RELAY INSPECTION WCH054SPROC11014
FRONT FOG LAMP RELAY CHECK

1. Remove the front fog lamp relay from the
engine fuse box (UEC).
Symbol Description
A Front fog lamp relay
2. Check the terminal continuity.
Battery Terminal No. Remark

voltage Continuity Check
Terminal
Power is sup- No.1(30) connect Continu-
plied → Terminal ity
No.4(87)
Terminal
No.1(30) connect No con-
→ Terminal tinuity
Power is not No.4(87)
T supplied Terminal
No.2(86) connect Continu-
→ Terminal ity
AF
No.3(85)
DOIQC054R12042
R
D

REAR COMBINATION LAMP AND REAR LID LAMP / 51
REAR COMBINATION LAMP AND REAR LID LAMP WCH054SASSY11010
T
AF
R
DOIQC054R11036
D
Removal steps
1. Rear combination lamp assy
2. Rear lid lamp assy
T1 :0.196 - 0.294 kgm (1.96 - 2.94 Nm, 1.42 - 2.13 ft.lbs)

/ 52 REAR COMBINATION LAMP
REAR COMBINATION LAMP

WCH054SPROC11015

LED ASSY REPLACEMENT
1. Remove LED module tapping screw (2 pieces).
Symbol Description
A Tapping screw
DOIQC054R11037
2. Remove LED module as shown in the illustra-

tion.
Symbol Description
B LED module
T
AF
DOIQC054R11038
3. Disconnect connector LED module properly.

R
D
DOIQC054R11039
EXTERIOR LIGHTING WCH054GINFO11002
GENERAL INFORMATION
Exterior light module provides the following 2 functions.
These 2 functions are configurable in BCM EPROM memory.
1) Home Safe Light function
Home Safe Light function controls the external headlamp relay. This function can be used to activate
the headlamp on for a certain time to guide the way home for driver.
2) Fog Lamp function
Fog Lamp function controls the front and rear fog lamp external relays to control fog lamps and send
the fog lamp status to CAN bus.

EXTERIOR LIGHTING / 53
T
AF
R
DOINC054R09104
HOME SAFE LIGHT/ FOLLOW HOME LIGHT

D
DOINW005R09024
After ignition is off, within 10 minutes, turn the Combination Light Switch from OFF to HEADLAMP
position and back to OFF within 2 seconds :
• Headlamp will be turned on for 30 seconds or 60 seconds according to BCM EPROM memory config-
uration if all doors are closed.
• During this 30 or 60 seconds time, if BCM detects any door ajar, head lamp will be on for 180 seconds.
• During this 180 second, if all doors are closed again, head lamp will be on again for 30 or 60 seconds.
• The 180 seconds timer will be restarted if any door ajar again after all doors are closed.

/ 54 EXTERIOR LIGHTING
• By default, head lamp will be on according to specified duration when all doors are closed within
30 seconds.
T
AF
R
DOINC054R09105
FOG LAMPS
D
Front and Rear Fog Lamp
DOINW005R09004
If ignition is ON and the position lamp is ON

• front fog lamp is turned ON when front fog lamp switch is pressed.
If ignition is ON and position lamp is ON, and head lamp is ON or front fog lamp is ON
• Rear fog lamp is turned ON when rear fog lamp switch is pressed (if fitted).
• Fog lamp will be turned OFF, if fog lamp switch is pressed again for both front and rear fog controls.
If ignition is OFF or position lamp is OFF

• fog lamp will be OFF for both front and rear fog controls.
When ignition is ON and position lamp is ON but if front fog lamp is OFF and head lamp is O
• rear fog lamp will also be OFF.
Exterior lamps status output to CAN [Fog lamps]
• front and rear fog lamp status is sent to CAN bus.
TURN SIGNAL FLASHERS
The flasher function generates all the signals to drive the turn indicator lamps in response to either
internal or external requests.
T
AF
R
D
DOINC054R09106
These signals are a succession of ON and OFF states. Internal requests come from hardware inputs:
• Left Turn switch,
• Right Turn switch along with the
• Ignition status (Turn signal mode) and
• Hazard switch (Hazard mode)

DOINW005R09026
1: Turn Signals
2: Lane Change/Passing Signals
3: Lane Change/Passing Flashing
External request comes from other functions:
• CDL,
• DIAGNOSIS,
• for flasher acknowledgements (Acknowledgement Mode) and
• ATWS for alarm flasher (Alarm Mode) or
T
• by monitoring the vehicle speed in order to perform hazard on heavy braking (HOD Mode)
Turn signal:
AF
If ignition is on and left or right turn switch is turned on, the left or right turn light shall be turned
on.
Double frequency flashing in failure mode:
During turn signal mode, in case of output failures the flashing frequency is doubled.
Lane change:
R
As a special treatment of turn signal mode, if the turn switch is positioned either for a left or a right
turn, for a time between minimum 100ms and maximum 700ms and then set back to neutral position
- then the corresponding indicator lights located on the car must blink for
D
• 3 times from the moment the switch position is changed.

HAZARD FLASHING
DOINW005R09005
The flasher shall perform hazard sequence if:

• hazard switch is ON or
• crash signal is received.
Hazard sequence by hazard switch shall be stopped by pressing the hazard switch again.

Hazard sequence by crash shall be stopped by pressing the hazard switch.

Hazard mode sequence is the same as turn signal mode sequence.
Hazard On Deceleration
The flasher shall automatically perform hazard sequence if HOD is activated. It can be stopped by
pressing the hazard switch.
CENTRAL DOOR LOCK ACKNOWLEDGEMENT
Remote Central Door Lock Request Acknowledgement
When Lock, Unlock, Vehicle Search, Remind or CU/DU toggle request from remote transmitter is re-
ceived, the appropriate acknowledge sequence shall be started. The Remind and CU/DU toggle ac-
knowledge period and pulsed are the same as unlock acknowledgement.
Alarm Flashing When the Alarm flasher confirmation is requested Alarm sequence shall be started on
the output.
Flasher period and pulse definition
Default
Parameter Duty Cycle Description
Value
Turn signal period 706ms 0.5 Normal period of turn signal flashing
T
Failure turn signal Fast period of turn signal flashing (in case of bulb
353ms 0.5
period failure)
Hazard 706ms 0.5 Period of hazard flashing
AF
Alarm 1000ms 0.5 Period of hazard flashing during alarm running
Remote Transmit-
ter lock acknow- 1760ms 1 Period of flashing to acknowledge a CDL lock
ledgement period
Remote Transmit-
ter Unlock acknow- 1000ms 0.5 Period of flashing to acknowledge a CDL unlock.
R
ledgement period
Period of flashing to acknowledge a CDL vehicle
Vehicle Search 500ms 0.5
search.
D
Period of flashing to acknowledge a CDL mode

CDL Auto Relock 1760ms 1
change.
CDL Remind ac- Period of flashing to acknowledge a CDL remind
500ms 0.5
knowledgement request.
CDU/DDU mode Period of flashing to acknowledge a CDL CDU/DDU
500ms 0.5
toggle period mode toggle
Lane change signal
706 ms 0.5 Normal period of lane change signal flashing
period
Failure lane change Fast period of lane change signal flashing (in case
353 ms 0.5
signal period of bulb failure)
Remote Transmit- Period of flashing to acknowledge a key learning
1000ms -
ter key learning request
Acknowledgement request Number of Flashes

Central Door Locking 1 flash
Central Door Unlocking 2 flash
Central Door Vehicle Search 3 flashes
Central Door Auto Relock 1 flash

Acknowledgement request Number of Flashes

Central Door Remind 5 flashes
CU/DU mode toggle 2 flashes
As requested
Diagnostic Left or Right flashing with normal fre-
quency
Hazard As requested
Alarm request As requested
Key Learning 1 flash

Inspection proced-
ure no.
Turn signal lamps not working
Lane Change flashing is not working
Hazard Flashing is not working (Hazard on Deceleration
is also not working )
Vehicle search light function via Remote Search Request
T 1 WCH054TSHOT206
AF
is not working — Turn Signal Lamps not flashing
(Transmitter Key-OK)
Home Safe Light Function is not working (Transmitter
2 WCH054TSHOT207
Key-OK)
Front Fog Lamp is not working 3 WCH054TSHOT208
Headlamp is not working 4 WCH054TSHOT205
R
• Turn signal lamps are not working

D
• Lane Change flashing is not working

• Hazard Flashing is not working (Hazard on Deceleration is also not working)
• Vehicle search light function via Remote Search Request is not working – Turn Signal Lamps not
flashing (Transmitter Key-OK)

OK GO TO 2
1 Check the Bulbs
NG Replace
Check Fuses OK GO TO 3
• No. 14 (10 A) Ignition 1-BCM in the Panel Fuse Box
2 • No. 18 (15 A) Door Lock Power in the Panel Fuse Box
• No. 22 (10 A) Hazard Turn Power in the Panel Fuse Box NG Replace
and replace if necessary


Check the BCM Connectors C-15, C-16 and C-17 for proper OK GO TO 4
mating
Check the following connectors for proper mating and
connection:
3 • D-13 Turn Signal Lamp LH
• A-32 Front Turn Signal Lamp LH NG Repair/ Replace
• A-43 Front Turn Signal Lamp RH
• G-09 Rear Combination Lamp RH
• G-10 Rear Combination Lamp LH
Harness Side:
(a) Check Voltage between connector C-17 Pin No. 7 (Door
Lock Power) and
T
AF
4
NG Repair/ Replace
DOINC054R09135
R
OK: System Voltage

(b) Check Voltage between connector C-15 Pin No. 33 (Ig-
nition 1- BCM) and
D

OK: System Voltage


Disconnect the BCM Connectors and check at the Harness OK GO TO 6
Side:
5
NG Repair/ Replace
DOINC054R09145
Check Voltage between connectors C-16 Pin No. 14 (Turn
Signal Power) and
• C-17 Pin No. 8 (Ground Power)
OK: System Voltage
T OK GO TO 7
AF
R
6
NG Repair/ Replace
D
DOINC054R09147
Check Continuity between connectors C-16 Pin No. 4 (Left
turn lamp) and
• C-15 Pin No. 27 (Left turn lamp switch)
OK: Continuity
NG: No Continuity


Disconnect the BCM Connector C-15 and check at the Har- OK GO TO 8
ness Side:
7
NG Repair/ Replace
DOINC054R09145
Check Voltage between Connector C-16 Pin No. 14 (Turn
Signal Power) and
OK: System Voltage
T OK GO TO 9
AF
R
8
NG Repair/ Replace
D
DOINC054R09147
Check Continuity between connector C-16 Pin No.13 (Right
turn lamp) and
• C-15 Pin No. 9 (Right turn lamp switch)
OK: Continuity
NG: No Continuity


ness Side:
9
NG Repair/ Replace
DOINC054R09144
(a) Check Continuity between C-15 Pin No. 28 (Hazard
switch) and
• Body Earth
OK: Continuity OK (Hazard switch ON)
OK: No Continuity (Hazard switch OFF)
T
(b) Check the Wiring Harness, Connectors, Switches, Bulb,
AF
Relay and Repair/Replace if necessary
ness Side:
R
D
10
NG Repair/ Replace
DOINC054R09146
(a) Check Continuity between connector C-15 Pin No. 9
(Right turn switch) and
• Body Earth
•C-16 Pin No. 13 (Right turn lamp)
OK: Continuity (Turn switch ON)
OK: No Continuity (Turn switch OFF)


ness Side:
11
NG Repair/ Replace
DOINC054R09146
(a) Check Continuity between C-15 Pin No. 27 (Left turn
switch) and
• Body Earth
•C-16 Pin No. 4 (Left turn lamp)
OK: Continuity (Turn switch ON)
OK: No Continuity (Turn switch OFF)
T
AF
Disconnect Connectors C-15 and Meter Combination (ICU) OK GO TO 13
Connector D-09 and check the Continuity of the CAN Bus
Wire (Twisted Wire) at the Harness Side:
R
D
12
NG Repair/ Replace
DOINC054R09133
(a) Check Continuity between C-15 Pin No. 30 (CAN High
BCM) and
• (ICU) Connector D-09 Pin No. 21(CAN High ICU)
OK: Continuity
(b) Check Continuity between C-15 Pin No. 40 (CAN Low
BCM) and
• (ICU) Connector D-09 Pin No. 20 (CAN Low ICU)
OK: Continuity
(refer Electrical Wiring Circuit Diagrams – Exterior Lighting


OK GO TO 14
13 Check the trouble symptom Replace Body Con-
NG
trol Module (BCM)
Refer Inspection
Chart for Diagnosis
YES Trouble Codes on
14 Are any of the BCM's Diagnosis Trouble Codes displayed? page
WCH054TSHOT129
NO STOP
Home Safe Light Function is not working (Transmitter Key-OK)

OK GO TO 2
1 Check the Bulbs
NG Replace
2
T
• No. 01 (15 A) Headlamp RH in the Engine Junction Box
AF
• No. 02 (15 A) Headlamp LH in the Engine Junction Box NG Replace
• No. 09 (10 A) Int Lamp in the Engine Junction Box
• No. 10 (10 A) Ext Lamp (Position) in the Engine Junction Box
mating
Check the following connectors for proper mating and connec-
R
tion:
• D-14 Headlamp Switch
3 • A-27 Headlamp LH Repair/ Re-
NG
D
• A-48 Headlamp RH place

• A-28 Front Position Lamp LH
• A-44 Front Position Lamp RH
• G-09 Rear Combination Lamp RH
• G-10 Rear Combination Lamp LH


Disconnect connectors C-16 and C-17 and check at the Harness OK GO TO 5
Side:
Lock Power) and
4 Repair/ Re-
NG
place
DOINC054R09135
OK: System Voltage
T
(b) Check Voltage between connector C-15 Pin No. 33 (Ignition
AF
1- BCM) and
OK: System Voltage
Disconnect the BCM Connector C-15 and check at the Harness OK GO TO 6

Side:
R
D
5 Repair/ Re-
NG
place
DOINC054R09143
(a) Check Voltage between C-16 Pin No. 3 (Headlamp Relay)
and
• Body Earth
OK: System Voltage
(b) Check the Headlamp Relay No. 01 (20 A) and the Illumina-
tion Relay No. 13 (20 A) in the Engine Junction Box refer to
WCH054SPROC211


Connector D-09 and check the Continuity of the CAN Bus Wire
(Twisted Wire) at the Harness Side:
Check CAN
6 Bus Wire
NG (Twisted
Wire), refer
DOINC054R09133 WCH054TSHOT140
(a) Check Continuity between C-15 Pin No. 30 (CAN High BCM)
and
OK: Continuity
T
(b) Check Continuity between C-15 Pin No. 40 (CAN Low BCM)
AF
and
OK: Continuity
OK GO TO 8
R
7 Check the trouble symptom. Replace Body

NG Control Mod-
ule (BCM)
Refer Inspec-
D
tion Chart for

Diagnosis
YES
8 Are any of the BCM's Diagnosis Trouble Codes displayed? Trouble Codes
on page
WCH054TSHOT129
NO STOP
• Front Fog lamp not working

OK GO TO 2
1 Check the Bulbs
NG Replace
• No. 11 (15 A) Front Fog Lamp in the Engine Junction Box NG Replace


mating
Check the following connectors for proper mating and connec-
tion:
3 Repair/ Re-
• D-07 Center Switch Assy NG
• A-21x Front Fog Lamp Relay place
• A-31 Front Fog Lamp LH
• A-42 Front Fog Lamp RH
Disconnect connectors C-16 and C-17 and check at the Harness OK GO TO 5
Side:
Lock Power) and
4
T NG
Repair/ Re-
AF
place
DOINC054R09135
OK: System Voltage
R

1- BCM) and
D
OK: System Voltage


Side:
5 Repair/ Re-
NG
place
DOINC054R09145
Check Voltage between C-16 Pin No. 2 (Front Fog Lamp Relay)
and
•C-17 Pin No. 8 (Ground Power)
T
OK: System Voltage (Front Fog Lamp ON-Ignition )
OK GO TO 7
AF
R
6 Repair/ Re-
NG
place
D
DOINC054R09146
Check Continuity between C-15 Pin No. 35 (Front Fog Lamp
Switch) and
• Body Earth
OK: Continuity OK (Fog Lamp Switch ON)
OK: No Continuity (Fog Lamp Switch OFF)
(c) Check the Wiring Harness, Connectors, Switches, Bulb, Relay
and Repair/Replace if necessary


7 Repair/ Re-
NG
place
DOINC054R09133
and
OK: Continuity
T
AF
and
OK: Continuity
OK GO TO 9
R
8 Check the trouble symptom. Replace Body

NG Control Mod-
ule (BCM)
Refer Inspec-
D
tion Chart for

Diagnosis
YES
on page
WCH054TSHOT129
NO STOP
Headlamp is not working

Diagnosed Item Probable Cause
• stuck or short circuit to KL30 (Battery)
Headlamp circuit and headlamp external Relay • malfunction of the wiring harness/connectors
failure • malfunction of the Combination switch
• malfunction of the bulb


• No. 14 (10A) Ignition 1 - BCM in the Panel Fuse Box
1 • No. 18 (15A) Door Lock Power in the Panel Fuse Box Repair/ Re-
• No. 01 (15A) Headlamp Power in Engine Junction Box NG
place
• No. 02 (15A) Headlamp Power in Engine Junction Box
mating
Disconnect connectors C-16 and C-17 and check at the Harness
Side:
Check Voltage between connector C-17 Pin No. 7 (Door Lock
Power) and
T
2 Repair/ Re-
NG
place
AF
DOINC054R09135
OK: System Voltage
R
1- BCM) and
OK: System Voltage
D


Side:
3 Repair/ Re-
NG
place
DOINC054R09143
(a) Check Voltage between C-16 Pin No. 3 (Headlamp Relay)
and
• Body Earth
OK: System Voltage
T
(b) Check the Wiring Harness, Connectors, Switches, Bulb, Relay
and Repair/Replace if necessary
AF
R
D
Check CAN
4 Bus Wire
NG (Twisted
Wire), refer
and
OK: Continuity
and
OK: Continuity

/ 72 INTERIOR LIGHTING

OK GO TO 6
5 Check the trouble symptom
NG Replace BCM
Refer Inspec-
tion Chart for
Diagnosis
YES
on page
WCH054TSHOT129
NO STOP
INSPECTION CHART FOR DIAGNOSIS TROUBLE CODES WCH054TSHOT11010
Fault Code Diagnosis Item Reference page

Lamp turn signal left circuit failure – circuit open
B1499
or short to battery
Lamp turn signal right circuit failure – circuit
B1503
open or short to battery
Hazard warning switch circuit failure – short cir- Exterior Lighting (refer to page
B1875
B2281
cuit to GND
T
Right turn switch circuit failure – short circuit to
WCH054TSHOT180)
AF
GND
Left turn switch circuit failure – short circuit to
B2282
GND
Front fog lamp circuit failure – short circuit to Exterior Lighting (refer to page
B1695
GND WCH054TSHOT203)
R
INTERIOR LIGHTING WCH054GINFO11003
GENERAL INFORMATION
Interior Lighting consist of the following:
D
Interior Lights/Lamps Specification Quantity of Bulb

Room lamp 8W 1
Map/personal lamp 10 W 3
Luggage compartment lamp 10 W 1
Key illumination LED 1.5 W —
Which is controlled by BCM. The Interior Lighting functionality in BCM are divided to two sub-functions
as follows:
1. To control the Interior lights – to activate and deactivate the interior lights (room lamp, map lamp,
luggage compartment lamp and key illumination LED)
2. To control the battery saver relay (BSR) – to activate and deactivate battery saver relay.
BATTERY SAVER CONTROL
The Battery Saver Control function is to control the BSR where the BSR will activate and deactivate
when one or more of the below trigger conditions are changed:
1. Driver door status
2. Passenger door status
3. Rear left door status

INTERIOR LIGHTING / 73
4. Rear right door status

The BSR is switched on and the battery saver timer is reloaded when either of following events occurs:
• Ignition status changes
• Any door status changes
• Unlock demand occurs (either remote or local requests)
The BSR will be automatically disconnected 20 minutes after it was turned ON
INTERIOR LIGHTING CONTROL
The Interior Lighting Control function is to control the activation and deactivation of the interior
lights such as fade-in, fade-out etc. when following condition is met
1. Fade-In when either one of the following conditions are met
• Any door is opened (Ignition ON)
• Ignition is switched OFF
• Unlock demand occurs while ignition switch is in Off position
2. Fade–Out when either one of the following conditions is met
• Ignition is switched ON and
• all doors are closed
• Lock demand (either remote or local request) occurs, while ignition switch is in Off position and
all doors are closed
T
• 30 seconds has elapsed since the last door was closed (while the car is not centrally locked)
• 30 seconds has elapsed since the interior light was turned on or whichever occurs last
• The last door is closed while the car is centrally locked.
3. Immediately SWITCHED OFF when
AF
• 15 minutes has elapsed since the last restart of the battery saver timer.
R
D

T
AF
R
DOINC054R09108
D

BATTERY SAVER
T
AF
R
DOINC054R09109
The state diagram as shown illustrates the battery saver relay management in case battery voltage is
in normal range.
D

INTERIOR LIGHTS MANAGEMENT
T
AF
R
DOINC054R09110
The state diagram illustrates the interior lights management in case battery voltage is in normal range.
INTERIOR LIGHTS BEHAVIOR
D
Here the 30 seconds time is the same with the auto re-locking time in BCM nonvolatile memory.
FADE-IN/ FADE-OUT
The fade-in phase draws a linear curve and is completed in 2.8 seconds (Fade-In Time). The fade-in
phase is performed in:
• 2.8 seconds (Fade-In Time)
• steps of 40 microseconds (Fade-In Step).
The fade-out phase draws a linear curve and is completed in 3.4 seconds (Fade-Out Time). The fade-
out phase is performed in:
• 3.4 seconds (Fade-Out Time)
• steps of 40 microseconds (Fade-Out Step).
REMOTE ILLUMINATED ENTRY (APPROACH LAMPS)
• The interior lights will fade-in after remote unlock request is received from the RKE Transmitter Key.
• The interior lights will fade-out after remote lock request is received from RKE Transmitter Key.

Items Specification
Room lamp & Map(Personal) lamp 12 V, 10 W
Interior lamps
Luggage room lamp 12 V, 10 W
Set of Diagnostic Proton For vehicle diagnos-

EZT0038 Advance Diagnostic is, ECU flashing and
DOIIC11AR07018
Removal of front
bumper mounting
clips, combination
MB990784
T Ornament remover
meters lower cover,
door mirror and
housing cover,
AF
quarter assy trim
DOIHC051R04017
cap and center
panel assy.

R
Inspection proced-
ure no.
D
Interior Lights (Room Lamp, Map Lamp, Luggage Compart-

ment Lamp and Key Illumination) is not working when 1 WCH054TSHOT175
one or more doors are opened or switched on manually
2 WCH054TSHOT176
ment Lamp and Key Illumination) is always on
ment Lamp and Key Illumination) Fade In and Fade Out 3 WCH054TSHOT179
Sequence is not working
Remote Illuminated Entry (Approach Lamps) is not working
4 WCH054TSHOT181
when Remote Lock/Unlock Request is activated

Interior Lights (Room Lamp, Map Lamp, Luggage Compartment Lamp and Key Illumination) is not
working when one or more doors are opened or switched on manually
Probable Cause
• Bulb Blown
• Malfunction of the BCM
The cause may be a blown bulb or no power to the Interi-
or Lighting and/or the BCM • Malfunction of the Interior Lighting
switch
• Malfunction of the wiring harness or
connector (open or short circuit)

YES
WCH054TSHOT129
NO GO TO 2
2 Check the Bulbs?
Check Fuses:
T OK
NG
OK
GO TO 3
Replace the Bulbs
GO TO 4
AF
Box
3 • No. 18 (15 A) Door Lock Power in the Panel Fuse Replace the Fuse and
Box NG
GO TO 4
• No. 17 (10 A) Battery Saver Power in the Panel
R
Fuse Box
D


Check the BCM Connectors C-15, C-16 and C-17 OK GO TO 5
for proper mating
Disconnect connectors C-16 and C-17 and check at
the Harness Side:

wiring harness

T DOINC054R09135
AF
OK: System Voltage
(b) Check Voltage between connector C-15 Pin No.
33 (Ignition 1- BCM) and
OK: System Voltage

R

• D-16 Steering Lock Switch
D
• E-13 Front map lamp

• E-17 Center room lamp
5 • G-07 Luggage room lamp (+) Repair the affected
NG
connectors
• G-08 Luggage room lamp (-)
• C-15 BCM
• C-16 BCM
• C-17 BCM
• Disconnect BCM connector C-16 and measure at OK GO TO 7

the harness side:
• Voltage between Pin No. 6 (Battery Saver Power)
6 Repair or replace con-
and body earth
NG nector or the wiring
OK: Battery voltage harness
Ignition: OFF


the harness side:
• Continuity between Pin No. 15 (Battery Saver
Output) and body earth
• Continuity between Pin No. 1 (Interior Lamps) Repair or replace the
7
and body earth NG switch, connector or
OK: Continuity OK the wiring harness
• Switch On the Interior Lights One by One

Ignition: OFF

8 no. 2 and BCM NG Repair/Replace
Check the door switch by pressing the door contact OK GO TO 10
switch one by one:
9
Observe the door ajar signal in the Combination NG Replace
Meter
Check the following connectors:

• C-02, C-03, C-13, C-15, C-16, C-17
T OK GO TO 11
AF
10
NG Repair/Replace
• E-01, E-04, E-06, E-09

11 and BCM, C-15 NG Repair/Replace
Check the continuity of the Ignition Key cylinder OK GO TO 13
12
R
switch (refer to GROUP 54-IGNITION SWITCH) NG Repair/Replace

D
13 C-16 NG Repair/Replace

14
NG Replace BCM
15 Codes on page
NO STOP

Interior Lights (Room Lamp, Map Lamp, Luggage Compartment Lamp and Key Illumination) is always
on
Probable Cause
• Door contact switch short to ground
• Malfunction of the Interior Lighting
This may be caused by a faulty door contact switch, faulty switch
interior lighting switch or the malfunction of the BCM
connector (open or short circuit)

Does all the Interior Lighting Fade-Out automatic- Check all the Interior
ally after 20 minutes? YES Lighting switch's posi-
tion?
• Make sure that all the doors, hood and tailgate
are closed
1
• Make sure that Transmitter Key is NOT in the Key
Cylinder
T
• Make sure that all the Interior Lighting switches
NO GO TO 2
AF
are in OFF or DOOR position

Are any of the BCM's Diagnosis Trouble Codes dis- for Diagnosis Trouble
YES
WCH054TSHOT129
NO GO TO 3
R
Check all the door contact switch by: OK GO TO 4

• Opening and closing the doors one by one and
observe the door ajar signal in the Combination
D
3 Meter Repair/Replace the

NG
faulty Contact Switches
• Check the Continuity of the Door Contact Switch,
refer MODULE 1.1, Group 42
4 • C-02, C-03, C-13, C-15, C-16, C-17

NG Repair/Replace
• E-01, E-04, E-06, E-09

5 and BCM, C-15 NG Repair


the harness side:
• Continuity between Pin No. 15 (Battery Saver
Output) and body earth
• Continuity between Pin No. 1 (Interior Lamps) and Repair or replace the
6 body earth Interior Lighting
NG
OK: Continuity OK (when switched ON) switch, connector or
the wiring harness
OK: NO Continuity (when switched OFF)
Ignition: OFF
Check the harness wire between the fusible link no. OK GO TO 8

7 2 and BCM NG Repair/Replace
Check the continuity of the Ignition Key cylinder OK GO TO 9
8 switch (refer to GRP 54-IGNITION SWITCH) NG Replace
9
Check the harness wire
T
• Between ignition key cylinder, D-16 and BCM, C-
16
OK GO TO 10
AF
NG Repair
OK GO TO 11
NG Replace BCM
R
Are any of the BCM's Diagnosis Trouble Codes dis- YES

11 Codes on page
played? WCH054TSHOT129
NO STOP
D
Interior Lights (Room Lamp, Map Lamp, Luggage Compartment Lamp and Key Illumination) Fade In
and Fade Out Sequence is not working
Probable Cause
This may be caused by a faulty door contact switch, faulty • Malfunction of the Interior Lighting
interior lighting switch, malfunction of the wiring harness switch
or the connector or malfunction of the BCM • Malfunction of the wiring harness or
connector


Does all the Interior Lighting Fade-Out automatically Check all the Interi-
after 20 minutes? YES or Lighting switch's
position?
• Make sure that all the doors, hood and tailgate are
closed
1
• Make sure that Transmitter Key is NOT in the Key
Cylinder NO GO TO 2
• Make sure that all the Interior Lighting switches are
in OFF or DOOR position
Refer Inspection
Chart for Diagnosis
Are any of the BCM's Diagnosis Trouble Codes dis- YES Trouble Codes on
2 played? page
WCH054TSHOT129
NO GO TO 3
• No. 14 (10 A) Ignition 1 - BCM in the Panel Fuse Box
3
Box
T
• No. 17 (10 A) Battery Saver Power in the Panel Fuse
NG
Replace the Fuse
and GO TO 4
AF
Check all the door contact switch by: OK GO TO 5

• Opening and closing the doors one by one and ob-
4 serve the door ajar signal in the Combination Meter Repair/Replace the
NG faulty Contact
• Check the Continuity of the Door Contact Switch, Switches
R
5 • C-02, C-03, C-13, C-15, C-16, C-17

D
NG Repair/Replace
• E-01, E-04, E-06, E-09

6 BCM, C-15 NG Repair
• Disconnect BCM connector C-16 and C17 and meas- OK GO TO 8
ure at the harness side:
• Continuity between Connector C-16, Pin No. 15
(Battery Saver Output) and C-17, Pin No. 8 (Ground)
Repair or replace
7 OK: Continuity OK (when switched ON) the Interior Lighting
NG
OK: NO Continuity (when switched OFF) switch, connector or
the wiring harness
Ignition: OFF



Check the Ignition Key cylinder switch continuity (refer OK GO TO 10
9 to GRP 54-IGNITION SWITCH) NG Repair/Replace
10
• Between ignition key cylinder, D-16 and earth. NG Repair/Replace
OK GO TO 12
NG Replace BCM
Refer Inspection
Chart for Diagnosis
12 page
played?
WCH054TSHOT129
NO STOP
Remote Illuminated Entry (Approach Lamps) is not working when remote Lock/ Unlock request is
activated
T Probable Cause
AF
This may be caused by a faulty door contact switch, faulty • Malfunction of Interior Lighting switch
interior lighting switch, malfunction of the wiring harness
or the connector or malfunction of the BCM • Malfunction of the wiring harness or
connector
R

YES GO TO 2
D
Does all the Central Door Locking and the Remote Check the Central
1 Keyless Entry function work properly? Door Locking and
NO
Remote Keyless Entry
System
Refer Inspection
Chart for Diagnosis
2 played? page
WCH054TSHOT129
NO GO TO 3
• No. 17 (10 A) Battery Saver Power in the Panel Fuse
Box NG
GO TO 4
Box


Check all the doors contact switches by: OK GO TO 5
• Opening and closing the doors one by one and ob-
4 serve the door ajar signal in the Combination Meter Repair/Replace the
NG faulty Contact
• Check the Continuity of the Door Contact Switch, Switches
5 • C-02, C-03, C-13, C-15, C-16, C-17

NG Repair/Replace
• E-01, E-04, E-06, E-09

6 BCM, C-15 NG Repair/Replace
• Disconnect BCM connector C-16 and C17 and meas- OK GO TO 8
ure at the harness side:
• Continuity between Connector C-16, Pin No. 15
(Battery Saver Output) and C-17, Pin No. 8 (Ground)
Repair or replace the
7 OK: Continuity OK (when switched ON)
OK: NO Continuity (when switched OFF)
T NG
Interior Lighting
switch, connector or
the wiring harness
AF
Ignition: OFF

Check the Ignition Key cylinder switch continuity (refer OK GO TO 10
R
9 to GRP 54-IGNITION SWITCH) NG Repair/Replace

D
10
• Between ignition key cylinder, D-16 and earth. NG Repair
OK GO TO 12
NG Replace BCM
Refer Inspection
Chart for Diagnosis
12 page
played?
WCH054TSHOT129
NO STOP

/ 86 HIGH MOUNTED STOP LAMP
HIGH MOUNTED STOP LAMP WCH054SASSY11011
T
AF
R
DOIQC054R11040
D
Removal steps
1. Tapping screw
2. High mounted stop lamp assy
Symbol:
a — Rear roof rail
b — Rear glass
c — Headlining
T1 : 0.25 kgf.m ± 15%

HIGH MOUNTED STOP LAMP / 87
T
AF
R
DOIQC054R11041
Removal steps
1. Housing assy
D
2. LED assy
3. Cover

/ 88 HIGH MOUNTED STOP LAMP
HIGH MOUNTED STOP LAMP REMOVAL

1. Use the special tool (MB990784) as shown in
the picture to pry out the cap.
Symbol Description
A Cap
B High mounted stop lamp
DOIQC054R12044
2. Remove the 2 pieces tapping screw of high

mounted stop lamp.
Symbol Description
A Tapping screw
B Cap
T
C High mounted stop lamp
AF
DOIQC054R12045
3. Disconnect the high mounted stop lamp

connector
R
Symbol Description
A Connector
B High mounted stop lamp
D
DOIQC054R11047

LICENCE PLATE LAMP ASSY / 89
LICENCE PLATE LAMP ASSY WCH054SASSY11012
T
AF
R
DOIQC054R11048
D
Pre-removal end post-installation operation

• Trunk lid garnish removal and installation (Refer to GROUP 051 — Garnish).
Removal steps
1. Grommet
2. Licence plate lamp assy
3. Tapping screw

/ 90 LICENCE PLATE LAMP ASSY
LICENCE PLATE LAMP REMOVAL

WCH054SPROC11017

1. Remove the 2 pieces tapping screws of li-
cence plate lamp assy.
Symbol Description
A Tapping screw
DOIQC054R11049
T
AF
R
D

SWITCH CENTER ASSEMBLY / 91
SWITCH CENTER ASSEMBLY WCH054SASSY11013
T
AF
R
DOIQC054R11050
D
Pre- removal and post- installation operation

• Cover frame shift lever assy (Refer to Group 52A – Floor Console)
Removal steps
1. Center panel assy
2. Tapping screw

/ 92 SWITCH CENTER ASSEMBLY
T
AF
R
DOIQC054R12016
Removal steps
D
2. Switch center assembly

3. Switch assy – left
4. Switch assy – right

REAR DEFOGGER / 93
CENTER PANEL ASSY AND SWITCH CENTER

ASSEMBLY REMOVAL
1. Use the special tool as shown in the figure
to pry out the cover frame shift lever assy.
DOIQC054R12031
REAR DEFOGGER WCH054GINFO11004
GENERAL INFORMATION
The Rear Defogger
The rear Defogger/defogger function can be turned on or off via the Rear Defogger switch located
on the center switch console on the Instrument panel. The Rear Defogger function can be enabled
or disabled in the BCM EEPROM.
T
AF
R
D
DOINW005R09006
The BCM will store the current status of the Rear Defogger state in EEPROM when the state changes.
The BCM will transmit the current status of the Rear Defogger state on CAN Bus.

/ 94 REAR DEFOGGER
T
AF
R
DOINC054R09107
INSPECTION CHART FOR DIAGNOSIS TROUBLE CODES

D
CAUTION
Always conduct the 'Self Test' first before checking for any fault codes (DTC).

Rear window defrost circuit failure – short circuit Rear Defogger (refer to page
B1343
to GND WCH054TSHOT136)

CLOCK / 95
CLOCK WCH054SASSY11014
T
AF
R
DOINC054R09165
D
Removal steps
2. Clock

/ 96 CLOCK
CENTER PANEL ASSY AND CLOCK REMOVAL

to pry out the center panel assy properly.
DOINC054R09022
2. Disconnect the connectors of switch front

fog lamp, rear window demister, hazard
warning, air-conditioner control switch and
clock.
Symbol Description
A Clock connector
T B
Front fog lamp, rear win-
dow demister and hazard
warning switch connector
AF
Air-conditioner control
C
switch connector
DOINC054R09023
R
D

COLUMN SWITCH / 97
COLUMN SWITCH WCH054SASSY11015
T
AF
R
DOIQC054R12020
D
CAUTION
(1) For vehicle with SRS, please refer to group 52B- SRS Service Precautions Air Bag Module and
clock spring before removing the air bag module.
• Steering wheel assy removal and installation (Refer to GROUP 37A – Steering).
• Panel assy lower (driver side) removal and installation (Refer to GROUP 52A – Interior).
Removal steps
• Disconnect the negative terminal of the battery and tape (A) the terminal.
1. Column cover upper
2. Column cover lower
3. Clock spring
4. Column switch

/ 98 COLUMN SWITCH
Symbol Description
Switch connector A
A (Lighting/ Dimmer/
Passing)
Switch connector B (Turn-
B
signal lamp)
DOINC054R09037
LIGHTING SWITCH, DIMMER / PASSING SWITCH AND TURN-SIGNAL LAMP SWITCH CHECK
Switch position Connector A (Terminal No.)
OFF —
Terminal No.4 connect → Terminal
TAIL
LIGHTING SWITCH No.2
T
HEAD
No.2
LOWER
AF
No.6
DIMMER SWITCH
UPPER
No.6
No.2 connect → Terminal No.5 and
LOWER
R
No.6
PASSING SWITCH
No.2 connect → Terminal No.5 and
UPPER
D
No.6
Switch position Connector B (Terminal No.)
LH
No.8
TURN SIGNAL LAMP SWITCH OFF —
RH
No.8

START/STOP BUTTON / 99
START/STOP BUTTON WCH054GINFO11011
INTRODUCTION
With the SSB handling and power moding function, ABCM shall control the vehicle ignition status for
ACC,IG1 and Cranking.
Information regarding to the SSB is received via hard-wired inputs to the ABCM. For the safety concept,
2 redundant digital inputs are used, one is low active and the other one is high active. According to
the SSB inputs and other vehicle information, ABCM shall control the vehicle ignition status through
the external relays.
• ACC status will be completely controlled by ABCM. IG1 status is controlled via ABCM and the self
latched relays in the junction box.
• Cranking status is controlled via both ABCM and EMS.
• When the Cranking status is enabled by ABCM, the IG2 status will be deactivated by the same
output signal from ABCM.
• In order to provide the ignition status to the user, 2 additional LEDs are driven by the BCM, besides
the CAN signals sent to cluster by ABCM.
T
AF
R
D
DOIQC054R11042
NOTE
(1) Pushing start stop button once or long press has no influence on cranking duration (trigger only)
(2) After the engine is running the cranking will stop automatically
(3) If the engine is not running the cranking will stop after 6 secs
(4) After cranking time out, cranking can be started again by pushing the start stop button
(5) Cranking is interrupted when start stop button pressed again

/ 100 START/STOP BUTTON
Operating voltage range 6 V ~ 16 V
Active current < 500 mA
Quiescence Current < 1mA
CHECK AT START STOP BUTTON CONNECTOR WCH054SPROC11028
T
AF
DOIQC054R11044
R
D
DOIQC054R11043
Terminal
(Measure at harness Signal Checking requirements Standard value
side)
1 SSB SW2 Ignition switch : ON < 0.01 A
2 - - -
3 LED GREEN Ignition switch : ON < 0.02 A
4 - - -
5 GND Ignition switch : ON < 0.02 A
6 SSB SW1 Ignition switch : ON < 0.02 A
7 SSB B/GND Ignition switch : ON < 0.02 A
8 LED ORANGE Ignition switch : ON < 0.02 A
9 - - -

WIPER AND WASHER SYSTEM / 101
Terminal
(Measure at harness Signal Checking requirements Standard value
side)
10 B+ - 12 V / < 0.02 A
WIPER AND WASHER SYSTEM WCH054GINFO11005
GENERAL INFORMATION
FRONT WIPER
The front wiper function is enabled only after the ignition is switched ON. If the ignition is switched
OFF, the complete wiper function returns to the default state and the wiper outputs are switched off.
It is configurable in BCM EEPROM. Below are the several different functions of the wiper:
• Off,
• Intermittent mode (user programming dwell time),
• Front and Rear Wash mode,
• Drip wiping,
• Mist wiping,
• Low Speed continual wipe mode,
T
• High Speed continual wipe mode.
AF
R
DOINW005R09027
D
Symbol Description
OFF Wiper OFF
1 Intermittent Wiping
2 Low Speed Wiping
3 High Speed Wiping
If the vehicle is moving with the front wiper running at low speed and the vehicle comes to a stop
(0km/h speed), the wiper will switch to intermittent mode automatically. When the vehicle speed is
increased, the front wipers will automatically return to low speed again.

/ 102 WIPER AND WASHER SYSTEM
T
AF
R
DOINC054R09111
Mist wiping
When the Wiper Switch Lever is pulled towards the driver and released immediately, the below
D
functions will be activated:

• the front washer and wiper (as described in Prolongation wiping)
Front wiping (High/Low speed) control
When the front wiper handle is moved to high speed position, the front wiper moves at high speed
immediately.
When the front wiper handle is moved to low speed position, the front wiper moves at low speed
immediately.
Front wiping intermittent control
When the front wiper handle is moved to intermittent mode, the wiper will be activated immediately
in intermittent mode (beginning with a wipe cycle, and then a stop in dwell time). The wiper motor
will only be activated when Ignition switch is ON.
DWELL-time Programming
Front wiper DWELL time can be set by the user with the front wiper switch.

Front wash wiping
DOINW005R09029
Front wash wiping has 3 modes:

• Wash wiping,
• Prolongation wiping and
• Drip wiping mode
When the front washer switch is pressed ON for 15 seconds, the front wiper will be stopped immediately
and then followed by a drip wiping sequence. When the front wiper handle is in OFF position and
T
the Front Washer Switch is pressed , the washing mode is activated,
• after 280ms, the wiper is activated in low speed.
AF
• During washing mode, the front wiper motor is activated continuously in slow speed.
When front wiper handle is in OFF position and the Front Washer Switch is pressed, the front wiper
motor will remain activated as long as the Front Washer Switch is being pressed.
Prolongation wiping
When front wiper handle is in OFF position and when the Front Washer Switch is pressed and is released
immediately, the front wiper motor will remain activated for another 3 complete wipe cycles before
R
it stops in the park position. For the last prolongation wipe cycle the wiper motor will be activated
for 480ms only. After this the relay will be turned off and the front wiper motor will reach the park
position.
D
Drip wiping:
When the front Washer Switch pressed and the front wiper motor is activated in continuous slow
speed. After releasing the Front Washer Switch, the prolongation wipes are performed.
From the moment the last prolongation wipe is completed (front wiper reaches park position and
stops), there will be an interval of 5s before the front wiper is again activated for a single drip wipe.
REAR WIPER
The Rear wiper has 4 different kinds of control mode:
• Off
• Reverse Gear Wipe
• Wash Wipe
• Continual Wipe
• Intermittent Wipe

DOINW005R09028
In the Off mode, the output relay is in the default state (OFF). In the Reverse Gear Wipe mode, the
rear wiper relay is activated when the reverse gear switch is activated and the front wiper is running.
The working mode depends on the front wiper working mode.
• In the wash wipe mode the rear wiper runs continually. After the rear washer switch is released, it
continues wiping for an additional 4 seconds.
• In the continual wipe mode, the rear wiper will run continuously in low speed.
T
• In the intermittent wipe mode, the rear wiper will run in intermittent mode.
The rear wiper function is affected by the ignition status and rear wiper control is configurable in
BCM EEPROM.
AF
R
D
DOINC054R09112

Rear Wiper Continual wipe

If rear wiper switched is ON, the rear wiper runs continually in low speed when ignition is ON and
the front wiper is running in high/low speed.
Rear Wiper Intermittent wipe
If the rear wiper switch is ON, the rear wiper runs in intermittent mode with a dwell time of 4.5s.
Rear Wash wiping
DOINW005R09029
T
When the rear washer switch is ON or pressed ON for 15 seconds, the rear wipe will be stopped imme-
diately and then followed by a drip wipe.
AF
The rear wiper is activated in the following sequence (Relay activation in washing mode) :
• Rear Wiper Pre Wash Time (280ms)
• Rear Wiper Prolongation Time: (4000ms)
• Rear Wiper Park Ack Off Time (480ms)
• Rear Wiper Drip Wipe Delay Default Time (4960ms)
Reverse Gear/Back Up wiping
R
When rear wiper handle is in OFF position and the rear washer switch is not pressed and if the reverse
gear is activated for at least 1000ms and the front wiper is running,
D
• the rear wiper relay is activated for 480ms,

• if front wiper is in high/low mode, rear wiper will run in low speed mode,
• if front wiper is in intermittent mode, rear wiper will also run in intermittent mode with a duty cycle
of 4.5s
Relay activation in reverse gear intermittent mode:
• Rear wiper Park Acq Off time (480ms)
• Rear wiper Reverse Gear wiper delay time (1000ms)
• The interval of rear wiper relay activation in reverse gear mode is 4.5s

Inspection proced-
ure no.
Front Wiper system not working (all speeds)
1 WCH054TSHOT199
Front Drip Wiping system not working
Rear Wiper system not working
Rear Drip Wiping system not working 2 WCH054TSHOT200
Reverse Gear Wiping system not working

Inspection proced-
ure no.
Front Washer system not working 3 WCH054TSHOT201
Rear Washer system not working 4 WCH054TSHOT202
• Front Wiper system not working (all speeds)

• Front Drip Wiping system not working

• No. 14 (10 A) (Ignition 1 - BCM) at the Panel Fuse Box
1 • No. 26 (20 A) (Frt Wiper Power) at the Panel Fuse Box Repair/ Re-
NG
• No. 28 (15 A) (Rear Wiper Power) at the Panel Fuse Box place
• No. 18 (15 A) (Door Lock Power) at the Panel Fuse Box
Check the BCM Connectors No. C15, C16 and C17 for proper OK GO TO 3
mating
T
AF
2 Repair/ Re-
NG
place
R
DOIGC13AR03129
Check the Continuity of the Ground Connections: Disconnect
the BCM Connectors No. C16 and C17 and check at the Harness
Side:
D
OK GO TO 4
Check the Wiper and Washer System Connectors No. A-01,
3 Repair/ Re-
A23x, A-46, A-47, D-19 and G-20 for proper mating NG
place


Disconnect the BCM Connectors No. C16 and C17 and check OK GO TO 5
4 Repair/ Re-
NG
place
DOINC054R09135
Check Voltage between No. C 16 Pin No. 17 (Front Wiper
Power) and
• No. C 17 Pin No. 8 (Ground Power)
• No. C 16 Pin No. 5 (Ground Signal)
OK: System Voltage (Ignition ON/ OFF)
T
Refer Electrical Wiring Circuit Diagrams – Wiper and Washer
AF
(b) Check Voltage between Connector C-15 Pin No. 33 (Ignition
1– BCM) and
OK: System Voltage
R
D


For Front Wiper Intermittent Speed functions: OK GO TO 6
Disconnect the BCM Connectors No. C15 and No. C 16 and
check at the Harness Side:
DOINC054R09152
(a) Check Voltage between No. C 15 Pin No. 7 (Frt Wiper Int
Switch)
5
• Body Earth
T
OK: System Voltage (Frt Wiper Int Switch ON - Ignition ON) NG
Repair/ Re-
place
AF
R
D
DOINC054R09155
(b) Check Continuity between No. C 15 Pin No. 7 (Frt Wiper
Int Switch)
• No. C 16 Pin No. 8 (Front Wiper Low Speed Output)
OK: Continuity OK (Frt Wiper Int Switch ON - Ignition OFF)
(c) Check the Wiring Harness, Connectors, Switches, Relay,
Wiper motor and Repair/Replace if necessary


For Front Wiper Low Speed functions: OK GO TO 7
DOINC054R09152
(a) Check Voltage between No. C 15 Pin No. 31 (Frt Wiper Low
Switch)
6
• Body Earth
T
OK: System Voltage (Frt Wiper Low Switch ON - Ignition ON) NG
Repair/ Re-
place
AF
R
D
DOINC054R09155
(c) Check Continuity between No. C 15 Pin No. 31 (Frt Wiper
Low Switch)
• No. C 16 Pin No. 8 (Front Wiper Low Speed Output)
OK: Continuity OK (Frt Wiper Low Switch ON - Ignition OFF)
(d) Check the Wiring Harness, Connectors, Switches, Relay,


For Front Wiper High Speed functions: OK GO TO 8
7 Repair/ Re-
NG
place
DOINC054R09170
(a) Check Voltage between No. A 01 Pin No. 2 (Frt Wiper High
Output)
• Body Earth
T
OK: System Voltage (Frt Wiper High Switch ON - Ignition ON)
(b) Check the Wiring Harness, Connectors, Switches, Relay,
AF
OK GO TO 9
8 Check the trouble symptom Replace Body
NG Control Mod-
ule (BCM)
Refer Inspec-
R
tion Chart for

Diagnosis
YES
D
on page
WCH054TSHOT129
NO STOP
• Front Washer system not working

• No. 14 (10 A) (Ignition 1 - BCM) at the Panel Fuse Box
1 • No. 26 (20 A) (Frt Wiper Power) at the Panel Fuse Box Repair/ Re-
NG
• No. 28 (15 A) (Rear Wiper Power) at the Panel Fuse Box place
• No. 18 (15 A) (Door Lock Power) at the Panel Fuse Box


mating
2 Repair/ Re-
NG
place
DOIGC13AR03129
the BCM Connectors No. C16 and C17 and check at the Harness
Side:
OK GO TO 4
Check the Wiper and Washer System Connectors No. A-01,
3 Repair/ Re-
A23x, A-46, A-47, D-19 and G-20 for proper mating
T
NG
place
Disconnect the BCM Connectors No. C16 and C17 and check OK GO TO 5
AF
R
D
4 Repair/ Re-
NG
place
DOINC054R09135
Check Voltage between No. C 16 Pin No. 17 (Front Wiper
Power) and
• No. C 17 Pin No. 8 (Ground Power)
• No. C 16 Pin No. 5 (Ground Signal)
OK: System Voltage (Ignition ON/OFF)
(b) Check Voltage between Connector C-15 Pin No. 33 (Ignition
1– BCM) and
OK: System Voltage


For Front Washer functions: OK GO TO 6
Disconnect the BCM Connectors No. C15 and check at the
Harness Side:
5 Repair/ Re-
NG
place
DOINC054R09152
(a) Check Voltage between No. C 15 Pin No. 21 (Front Washer
Switch) and
• Body Earth
T
OK: System Voltage (Front Washer Switch ON-Ignition ON)
AF
Pump motor and Repair/Replace if necessary
OK GO TO 7
NG Control Mod-
R
ule (BCM)
Refer Inspec-
tion Chart for
D
Diagnosis
YES
on page
WCH054TSHOT129
NO STOP
CAUTION
Always conduct the 'Self Test' first before checking for any fault codes (DTC).

Front wiper intermittent circuit failure – show
B1611
open circuit
Front wiper LO speed circuit failure – stuck or Wiper and Washer section (refer to
B1615
short circuit to ignition page WCH054TSHOT218)
Front wiper HI speed circuit failure – stuck or
B1616
short circuit to ignition


Rear wiper circuit failure – stuck or short circuit
B1612
to ignition Wiper and Washer section (refer to
Reverse gear switch circuit failure – stuck or short page WCH054TSHOT220)
B2116
circuit to ignition
Rear washer circuit failure – stuck or short circuit
B2114
to ignition Wiper and Washer section (refer to
Front washer circuit failure – stuck or short circuit page WCH054TSHOT221)
B2112
to ignition
SYSTEM BLOCK DIAGRAM WCH054TSHOT11021
The Front Wiper System is controlled by the BCM
T
AF
R
D
DOINC054R09071
INSPECTION PROCEDURE FOR FRONT WIPER DIAGNOSIS CODES

WARNING
PLEASE DISCONNECT THE BATTERY'S NEGATIVE (–VE) TERMINAL BEFORE DISCONNECTING OR RECON-
NECTING ANY OF THE BCM CONNECTORS

Fault Codes Diagnosed Item Probable Cause

• stuck or short circuit to battery
• malfunction of the wiring harness/connect-
B1611 Front wiper intermittent circuit failure
ors
• malfunction of the wiper motor
B1615 Front wiper low-speed circuit failure
ors
B1616 Front wiper high-speed failure
ors

• No. 14 (10A) (Ignition 1 - BCM) at the Panel Fuse Box
1 • No. 26 (20A) (Frt Wiper Power) at the Panel Fuse Box NG Replace
• No. 28 (15A) (Rear Wiper Power) at the Panel Fuse Box
mating
T
• No. 18 (15A) (Door Lock Power) at the Panel Fuse Box
Check the BCM Connectors No. C-15, C-16 and C-17 for proper OK GO TO 3
AF
Disconnect the BCM Connectors C-16 and C-17 and check at
the Harness Side:
(a) Check Voltage between C-16 Pin No.17 (Front Wiper Power)
and
R
D
2 Repair/ Re-
NG
place
DOINC054R09153
OK: System Voltage (Ignition ON)


For Fault Code B1611: Disconnect the BCM Connectors C-15 OK GO TO 4
and C-16 and check at the Harness Side:
(a) Check Voltage between C-16 Pin No.17 (Frt Wiper Power)
and
3 Repair/ Re-
NG
place
T DOINC054R09152
(b) Check Voltage between C-15 Pin No. 7 (Frt Wiper Int Switch)
• Body Earth
AF
OK: System Voltage (Frt Wiper Int Switch ON-Ignition ON)
For Fault Code B1615: Disconnect the BCM Connectors No. C- OK GO TO 5
15 and No. C-16 and check at the Harness Side:
(a) Check Voltage between C-16 Pin No. 17 (Frt Wiper Power)
and
R

D
4 Repair/ Re-
NG
place
DOINC054R09152
(b) Check Voltage between C-15 Pin No. 31 (Frt Wiper Low
Switch)
• Body Earth
OK: System Voltage (Frt Wiper Low Switch ON-Ignition ON)


For Fault Code B1616: Disconnect the BCM Connectors No. OK GO TO 6
C15 and C-16 and check at the Harness Side:
(a) Check Voltage between C-16 Pin No. 17 (Frt Wiper Power)
and
5 Repair/ Re-
NG
place
T
(b) Check Voltage between A-01 Pin No. 2 (Frt Wiper High
Output)
DOINC054R09170
AF
• Body Earth
OK: System Voltage (Frt Wiper High Switch ON-Ignition ON)
OK GO TO 7
R

NG Control Mod-
ule (BCM)
D
Refer Inspec-
tion Chart for
Diagnosis
YES
on page
WCH054TSHOT129
NO STOP
SYSTEM BLOCK DIAGRAM WCH054TSHOT11022
The Front and Rear Washer System is controlled by the BCM

T
AF
DOINC054R09071
R
D

T
AF
DOINC054R09075
R
INSPECTION PROCEDURE FOR FRONT AND REAR WASHER DIAGNOSIS CODES

WARNING
D

B2114 Rear washer circuit failure ors
• malfunction of the washer tank pump
motor
B2112 Front washer circuit failure ors
• malfunction of the washer tank pump
motor

• No. 14 (10A) (Ignition 1 - BCM) at the Panel Fuse Box
1 • No. 26 (20A) (Frt Wiper Power) at the Panel Fuse Box NG Replace
• No. 28 (15A) (Rear Wiper Power) at the Panel Fuse Box
• No. 18 (15A) (Door Lock Power) at the Panel Fuse Box


Check the BCM Connectors No. C-15, C-16 and C-17 for proper OK GO TO 3
mating
2 Repair/ Re-
NG
place
DOIGC13AR03129
the BCM Connectors C-16 and C-17 and check at the Harness
Side:
For Fault Code B2114: Disconnect the BCM Connectors and OK GO TO 4
T
AF
3
R
Repair/ Re-
NG
place
DOINC054R09152
D
(a) Check Voltage between C-15 Pin No. 34 (Rear Washer

Switch) and
• Body Earth
OK: System Voltage (Rear Washer Switch ON-Ignition ON)

/ 120 HORN

and check at the Harness Side:
4 Repair/ Re-
NG
place
DOINC054R09152
(a) Check Voltage between C-15 Pin No. 21 (Front Washer
Switch) and
• Body Earth
T
OK: System Voltage (Front Washer Switch ON-Ignition ON)
AF
OK GO TO 6
NG Control Mod-
ule (BCM)
R
Refer Inspec-
tion Chart for
Diagnosis
YES
D
on page
WCH054TSHOT129
NO STOP
HORN WCH054GINFO11006
GENERAL INFORMATION
HORN
The Horn is controlled by the BCM via the Horn switch on the Steering Wheel. BCM also controls the
horn activation during:
• Panic Alarm (acoustic warning via Horn)
• Perimeter Alarm (acoustic warning via Horn)

HORN / 121
BLOCK DIAGRAM
T
AF
R
DOINC054R09218
D

/ 122 HORN
T
AF
R
DOIQC054R12028

• Front bumper removal and installation (Refer to GROUP 051 – Front bumper.)
D
Removal steps
1. Front bumper
2. Horn assy (Dual shell)
3. Front bumper beam assy

HORN / 123
SERVICE POINT INSPECTION

WCH054SPROC11021
HORN SWITCH INSPECTION

1. Disconnect clock spring connector C- 19
(Harness side),
Symbol Description
A Steering wheel horn pad
B Clock spring
C Connector C- 19
2. Check continuity pin: 12 (Clock spring side)
DOIQC054R12029 to ground.
Condition Continuity
OFF (Horn pad depress) no continuity
ON (Horn pad pressing) continuity
INSPECTION CHART FOR DIAGNOSIS TROUBLE CODES

Fault Code Diagnosis Item
T Reference page
AF
Horn (refer to page
B1681 Horn switch circuit failure – short circuit to GND
WCH054TSHOT135)
R
D

/ 124 AUDIO ASSY
AUDIO ASSY WCH054SASSY11017
T
AF
R
DOIQC054R12034
D

• Cover frame shift lever assy (Refer to Group 52A - Floor Console
Removal steps
2. Audio assy
3. USB cable connector

AUDIO ASSY / 125
AUDIO ASSY REMOVAL

to pry out the center panel assy properly.
Symbol Description
A Center panel assy
2. Remove the audio assembly mounting screws
(4 pieces).
DOIQC054R12031
3. Press the connector lock and remove the an-

tenna (B) and GPS (A) connector.
Symbol Description
A GPS connector
B Antenna connector
T
C Connector lock
D Audio assy
AF
DOIQC054R12047
4. Press the connector lock and remove the au-

dio harness connector.
R
Symbol Description
A Connector lock
B Audio harness connector
D
C Audio assy
DOIQC054R12048

/ 126 ANTENNA
ANTENNA WCH054SASSY11018
T
AF
R
D
DOIQC054R12035

ANTENNA / 127
Antenna assembly removal steps

• High mounted stop lamp assy removal and installation (Refer to page 54/86 ).
1. Antenna pole
2. Antenna base
3. Feeder antenna connection point (To antenna assembly)
Feeder antenna removal steps (Roof)
• High mounted stop lamp assy removal and installation (Refer to page 54/86 ).
• Trims pillar removal and installation (Refer to GROUP 52A - Trims).
• Headlining removal and installation (Refer to GROUP 52A - Headlining).
3. Feeder antenna connection point (To antenna assembly)
4. Tape
5. Feeder antenna (Roof)
6. Feeder antenna connection point (To instrument panel assembly)
Feeder antenna removal steps (Ip)
• Trims pillar removal and installation (Refer to GROUP 52A - Trims).
• Audio assy removal and installation (Refer to page 54/124 )
• Instrumant panel assembly removal and installation (Refer to GROUP 52A - Instrumant panel as-
sembly).
6. Feeder antenna connection point (To instrument panel assembly)
7. Clips
8. Feeder antenna (Instrument panel assembly)
9. Feeder antenna connection point (To audio system)
T
AF
10. Ventilation duct assembly
T1 : 0.29 ± 0.09 Kgf.m
R
D

/ 128 SPEAKER
SPEAKER WCH054SASSY11019
T
AF
R
DOIQC054R12043
D
Front door speaker (A) removal steps

• Front door trim removal and installation (Refer to GROUP 042 – Body)
1. Front speaker assy
2. Screw groumet
Rear door speaker (B) removal steps
• Rear shelf trim removal and installation (Refer to GROUP 052A – Trims.)
3. Rear speaker assy
T1 : 0.15 ± 0.05 kgf.m

ALARM SYSTEM / 129
ALARM SYSTEM WCH054GINFO11007
GENERAL INFORMATION
ANTI THEFT WARNING SYSTEM (ATWS)
The Anti Theft Warning System (ATWS), when enabled in BCM EEPROM (non-volatile memory),
provides audible and visual alarm when an unauthorized access to the vehicle is detected while the
system is armed. The Visual alarm consists of activation of the vehicle's Turn Signal Lamps (Flashers).
The audible alarm is executed via a pulsed activation of an audible alarm device (horn) which is anti-
synchronous with the Turn Signal Lamps (Flashers) flashing.
Basically, ATWS consists of the following states:
1. DISARM: No alarm sequence, vehicle in DISARM state. The vehicle can be disarmed by remote
transmitter unlock request.
2. PRE-ARM: No alarm sequence, after Pre-arm time-out (3 seconds), vehicle transit to ARMED state.
3. ARMED: No alarm sequence, any enabled trigger change from inactive to active, will make vehicle
transit to ALARM state.
4. ALARM (PANIC ALARM): Full alarm sequence, only Unlock request from remote transmitter or
when CAN signal from EMS indicating an RPM value of more than 500 RPM for 500ms is received
on CAN bus will make the vehicle transit back to the DISARM state
5. REMIND: Remind warning sequence for any door ajar event will be given off, and all door close
T
event will stop REMIND warning sequence and make it transit to ARMED state. If door is still ajar
after REMIND timer time-out (10 seconds), ARM state will be entered.
The ATWS triggers are:
AF
R
D
DOINC054R09100

/ 130 ALARM SYSTEM
• Front Left Door ajar SW

• Front Right Door ajar SW
• Rear Left Door ajar SW
• Rear Right Door ajar SW
• Tailgate ajar SW
• Hood ajar SW
• Key-In SW
The alarm system status shall be stored in BCM EEPROM (armed/disarmed/alarm/pre-arm/ remind) and
must be restored after power on reset. The 4 recent alarm trigger history shall be stored in the EEPROM
and the most recent alarm trigger of the doors will be sent to CAN Bus after BCM is awake.
T
AF
R
D

ALARM SYSTEM / 131
T
AF
R
D
DOINC054R09068

/ 132 ALARM SYSTEM
ATWS STATE TRANSITION
T
AF
R
DOINC054R09099
STATE CONDITION
1. No Alarm sequence
D
DISARM
2. Can be Disarmed by remote transmitter unlock.
1. No Alarm sequence after Pre-Arm time out (3 seconds), state will
PRE-ARM
change to ARMED state.
1. No Alarm sequence.
ARMED 2. Any enabled trigger change from inactive to active, state will change
to ALARM state.
1. Full Alarm sequence.
2. Only UNLOCK request from remote transmitter or
ALARM
3. CAN EMS Signal of more than 500 RPM for 500ms will change the
state to DISARM
1. Remind warning sequence for any door ajar
2. Remind warning stop if all door close and the state will change to
REMIND ARMED.
3. IF door is still ajar after REMIND timer time-out (10 seconds), ARM
state will be entered.
For Remote Keyless Entry Initialization refer to BCM Special Function on page WCH054TSHOT150

ALARM SYSTEM / 133
PERIMETER ALARM
Perimeter Alarm via Vehicle Horn
When ATWS is in ALARM state, Alarm warning will be running as following:
• Flashers starts the visual alarm sequence for the time length 30 seconds, visual alarm sequence is
turn lights is on for 500ms, off for 500ms.
• Horn starts the acoustic alarm sequence for the time length 30 seconds, acoustic alarm sequence is
alarm horn is on for 500ms, off for 500ms.
• Acoustic Alarm sequence is reverse synchronized with visual alarm sequence. When visual alarm is
on, horn alarm is off, while visual alarm is off, horn alarm is on.
ATWS STATE
ATWS pre-arm and armed LED indicator output after RC_LOCK
After Lock request received from remote transmitter,
• ATWS perimeter alarm state will change from DISARMED to PRE-ARMED
• ATWS LED will flash for: (160ms ON and 160ms OFF) as long as the system stays in pre-arm state.
• After the ATWS state enters ARMED state, the ATWS LED will continue to flash for (160ms ON and
1920ms OFF).
• This flashing will continue as long as ATWS state is armed.
T
• In all other ATWS states (REMIND, ALARM and DISARMED) the ATWS LED Indicator will not flash.
ATWS LED INDICATOR
ATWS LED indicator for alarm history (only for key trigger alarm)
AF
If ignition is off, and If there is a latest alarm history trigger by key-in switch:
• Anti-theft LED indicator will execute the Key-In SW trigger blinking sequence with the 240ms ON
and 240ms OFF when the ATWS Perimeter Alarm State is changed to disarmed state
• When the Ignition is ON again, the alarm history blinking sequence will only execute once for alarm
triggering.
R
• Blinking of Key-In Switch trigger will stop immediately in case ignition becomes ON.
ATWS ALARM HISTORY
ATWS alarm history indication transmission via the CAN Bus
D
When ignition is OFF:

• latest alarm history trigger information for all doors including Tailgate and hood will be transmitted
via CAN Bus to the IP/Combination Meter while BCM is in WAKE UP state.
• Minimum 30s will be lasted for BCM transmits these signals after BCM enters WAKE UP state.
• Any renter WAKE UP will restart 30s timer.
• After ignition is ON, all signal transmission for alarm history will be cleared.
ATWS PANIC ALARM
After panic request is received from RKE Transmitter Key, ATWS will:
• Start the panic alarm sequence for 160 seconds.
• The visual and acoustic alarm sequence is the same as perimeter alarm.
• The running panic alarm can be stopped by a short press of any button on the RKE Transmitter Key
or
• Stopped automatically after 160 seconds.
• For domestic variants, the buzzer will chirp once for panic alarm.
ACOUSTIC ALARM MUTE (CONFIGURABLE)
Acoustic alarm including horn activation and buzzer chirp activation can be enabled or disabled in
BCM EEPROM .

/ 134 ALARM SYSTEM
DOOR AJAR ACOUSTIC AND/OR VISUAL REMINDING

Door ajar acoustic and/or visual reminding (acoustic reminding configurable)
When ATWS is in the remind State, Remind will be running as following:
• Flasher will run visual REMIND 5 times in the sequence of turn lights is on for 250ms, off for 250ms,
• Two buzzer chirping will be executed in the interval of 2 seconds.
• If any one of the 6 doors remains open after a delay of 10s is expired, ATWS State will be changed
to ARM state.
Note: Acoustic reminder can be disabled in EEPROM .
ALARM SYSTEM FEATURES WCH054SPROC11023
1. Arming
Press the lock button;
Symbol Description
1 Lock button
• All doors will be locked
DOINC054R09222
T
AF
• Turn signal indication lamps will flash once
• Buzzer will sound once
R
D
DOINC054R09226

ALARM SYSTEM / 135
If one of the rear doors, tailgate or hood is not

closed (except front door), remind warning will
transit to armed mode within 10 seconds.
Anti theft LED indicator in the meter cluster
will blink continuously, indicating the car is in
arm mode.
Symbol Description
A LED indicator
T
AF
DOINC054R09225
2. Disarming
Press the unlock button.
R
Symbol Description
2 Unlock button
• All doors will be unlocked
D
• Interior light will fade-out (if room lamp switch

at door position)
• Room lamp will be “ON” for 30 seconds
DOINC054R09223
• Turn signal indication lamps will flash twice

• Buzzer will sound twice
DOINC054R09226

/ 136 ALARM SYSTEM
NOTE:
Arm will not activate when the ignition key is in
the ignition key cylinder.
DOINC054R09227
3. Automatic re-arm
If the vehicle is in disarm mode and no door(s)/
hood/ tailgate is opened within approximately
30 seconds: relocking will automatically occur
and the system will be rearmed.
After auto relock, if the room lamp switches at
T
door position, the Interior Lights will fade-in.
• Turn signal indication lamps will flash one time
• Flash sequence is same as remote lock flasher
sequence
AF
DOINC054R09226
NOTE:
This feature will not activate if the ignition key
is left in the key cylinder.
R
D
DOINC054R09227
4. Driver door unlock *

The driver's door can be set to unlock individually
when the unlock button is pressed in.
To set the Driver's door unlock;
• Press lock and unlock buttons simultaneously
until the turn signal indication lamps flash for 2
times.
Symbol Description
1 Lock button
2 Unlock button
DOINC054R09236 • Press the unlock button once will unlock the
driver's door only.

ALARM SYSTEM / 137
• Press the unlock button once again will unlock

all other doors.
To reset the Driver's door unlock feature, repeat
the setting procedure above.
5. Vehicle search
When ignition is OFF and key is not inserted in
ignition cylinder, and vehicle is in armed mode,
if the lock button of the remote transmitter is
pressed twice successively, the vehicle search will
be activated.
• Turn signal indication lamps will flash and
buzzer will sound 3 times respectively.
T
AF
R
DOINC054R09237
D

/ 138 ALARM SYSTEM
6. Door(s)/ tailgate/ hood not closed, remind

mode
In the case of the doors, tailgate or hood not
properly closed, the vehicle will be arm mode
when the lock button is pressed.
By pressing the lock button;
Symbol Description
1 Lock button
A LED indicator
• Buzzer will sound 5 times
• Turn signal indication lamps will flash 5 times
• LED at the meter display will illuminates to in-
dicate whichever doors, hood or tailgate not
properly closed (within 3 seconds)
T
AF
DOINC054R09229
In this condition, press unlock once before closed

all doors, hood or tailgate that are not properly
closed. Press the arm button once to rearm.
R
Symbol Description
1 Lock button
D
2 Unlock button
NOTE:
Driver and front passenger door does not activ-
ate the remind mode, instead will reject the arm
mode command until the door is properly closed.
DOINC054R09230

ALARM SYSTEM / 139
7. Door(s)/ tailgate/ hood/ ignition/ starter

protection
The system will be activated as panic if door(s)/
tailgate/ hood is opened or the key is inserted in
the ignition key cylinder while the system is in
arm mode.
The LED at the meter display will blink to indicate
whichever doors, hood or tailgate is opened.
Symbol Description
A LED indicator
The horn will be in panic mode continuously for
30 seconds or until alarm is in disarm mode. Press
the disarm button once or use the manual over-
ride function (refer to item no.10) to disarm.
T
AF
DOINC054R09231
8. Anti-theft LED indicator for alarm history

The anti-theft LED indicator at the meter display
R
will blink to indicate whichever doors, hood or

tailgate is opened during the system is in arm
mode. If blink, it come from ignition key
D
intrusion.
Symbol Description
A LED indicator
When the ignition key is in “ON” position or
vehicle is armed again, all signals transmission
DOINC054R09232 for alarm history will be cleared.
9. Panic button
When pressing the panic button, the system will
function as panic;
Symbol Description
3 Panic button
DOINC054R09235

/ 140 ALARM SYSTEM
• Buzzer will sound continuously

• Hazard lights will flash rapidly
• LED at the meter display will blink continuously
Symbol Description
A LED indicator
Push panic button for 0.5 seconds to activate
panic and push again to disable.
This will serve as SOS signal during emergencies.
Pressing any button again will switch-off the car
horn and hazard lamps. The alarm system will
remain arm.
T
AF
DOINC054R09233
NOTE:
Panic will not be activated if the ignition key is
left in the key cylinder.
R
D
DOINC054R09227
10. Manual override system

In case of battery transmitter lost, to reset while
the system is in panic mode, start the engine.
Panic alarm will automatically stop.
The keyless entry system does not operate if the
ignition key is left in the key cylinder, or the ig-
nition key is in “ON” position.
The transmitter will operate within 20 m from
the centre of the vehicle. However, the operating
range of the transmitter may change if the
vehicle is located near a TV transmitting tower,
power station, or radio broadcasting station.
DOINC054R09234

ALARM SYSTEM / 141
If the following conditions are observed after

pressing the remote control, the self-contained
battery may need to be replaced. The doors
cannot be unlocked without the transmitter. In-
stead, the key can be used to lock or unlock the
doors. Replace battery of type Lithium Coin Cell
CR2032.
If your transmitter is lost, please contact your
authorized dealer for a replacement.
CAUTION
(1) Do not leave the transmitter where it may
be exposed to heat caused by the direct rays
of the sun.
(2) The transmitter is a precision electronic
device. Therefore, pay attention to the fol-
lowing:
• Do not impose shock on the transmitter.
• Keep the transmitter dry.
• Do not disassemble the transmitter.
T
For Remote Keyless Entry Initialization process
please refer to BCM Special Function on page
WCH054TSHOT150
AF
LITHIUM Coin Cell Type CR2032
Battery type
DC 3 V
R
Operating voltage range DC 2 V ~ 3.5 V

-20 °C (-4 °F) to 60 °C (140 °F) (Limited
Operating temp. range
Transmitter key by battery)
D
Storage temp. range -40 °C (-40 °F) to 85 °C (185 °F)

Max Working Current < 2.6 mA
Transmitting frequency 433.92 ± 0.1 MHz
Quiscence Current < 0.0015 mA
Total Dark (Quiscence) Current 5 mA (Max)
Operating Voltage
Normal 12 V
Body Control Module
Min 9V
(BCM)
Max 16 V
Operating Temperature -30 °C (-22 °F) to 75 °C (167 °F)
Storage Temperature -40 °C (-40 °F) to 85 °C (185 °F)

/ 142 ALARM SYSTEM
Current consumption 5 A (Max)
Sound level 105 dB to 118 dB
Operating Voltage
Normal 12 V
Min 10 V
Horn Assy
Max 15 V
Output power 65 W (Max)
Frequency 420 ± 25 Hz
Modulating tone LOW
Operating temperature -40 °C (-40 °F) ~ 85 °C (185 °F)
Current consumption 5 mA to 15 mA
Sound level 100 ± 10 dB
Operating Voltage
Normal 12 V
Buzzer Alarm Min 8V
Max
Frequency
Operating temperature
T 15 V
1.3 ± 0.5 KHz
-10 °C (14 °F) ~ 80 °C (176 °F)
AF
Storage temperature -10 °C (14 °F) ~ 90 °C (194 °F)
R
D

ALARM SYSTEM / 143
T
AF
R
D
DOINC054R09065

/ 144 ALARM SYSTEM
Pre-removal and pre-installation

• Lower driver side panel assy (Refer to GROUP 52A - Instrument Panel Assembly).
Please disconnect the Battery's negative (-ve) terminal before disconnecting and/or connecting the
Body Control Module (BCM)
Removal steps
1. Buzzer assy
2. Body Control Module (BCM)
Note:
The BCM is located under instrument panel nearby steering shaft side
T1 :0.5 ± 0.1 Kgf.m
T2 :0.5 ± 0.1 Kgf.m
T
AF
R
D

ALARM SYSTEM / 145
BODY CONTROL MODULE (BCM) REMOVAL

The Alarm System - Anti Theft Warning System
(ATWS) is controlled by the Body Control Module
(BCM) as shown above, which is located under-
neath the right hand side Instrument Panel.
1. Remove the fuse box cover.
2. Remove the lower driver side panel cover (2
pieces screw).
DOINC054R09095
T 3. Remove the 2 pieces nut flange Body Control

AF
Module (BCM) bracket.
R
D
DOINC054R09096
4. Disconnect all the Connectors connected to

the Body Control Module (BCM) as shown in
the illustration.
Symbol Description
BCM Connector connected
A to IP Harness Connector
No. C15
B to IP Harness Connector
No. C16
DOINC054R09097
C to IP Harness Connector
No. C17

/ 146 ALARM SYSTEM
5. Remove the Body Control Module (BCM).
DOINC054R09098
BUZZER REMOVAL
1. Remove the buzzer mounting bolt.
T
AF
DOINC054R09093
2. Disconnect buzzer harness connector and

remove the buzzer.
NOTE:
R
To reinstall all the above components in reverse

order.
D
DOINC054R09094
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

Refer to Group 00 – How To Use Troubleshooting/Inspection Service Points.
DIAGNOSTIC FUNCTIONS
1. DIAGNOSIS TROUBLE CODE CHECK
CAUTION
Always conduct the SELF-TEST first before checking for any fault codes.
Use PADT-07 to check for diagnosis codes (Refer to GROUP 00 – How To Use Troubleshooting/In-
spection Service Points).

ALARM SYSTEM / 147
NOTE
Connect the PADT-07 to the 16–pins diagnosis connector (black).
2. ERASING STORED DIAGNOSIS TROUBLE CODES
Refer to Group 00 – How To Use Troubleshooting/Inspection Service Points.

3. SELF-TEST
To conduct the SELF TEST refer to page WCH054TSHOT150 under Special Function menu no. 1]
SELF TEST.
4. DYNAMIC DATA DISPLAY
To check the Dynamic Data Display, refer to page WCH054TSHOT156.

5. REMOTE KEYLESS ENTRY INITIALIZATION
To conduct the REMOTE KEYLESS ENTRY INITIALIZATION refer to page WCH054TSHOT150 under
Special Function menu no. 4] REMOTE KEYLESS ENTRY INITIALIZATION.
T
WCH054TSHOT11025
Inspection
procedure no.
AF
Alarm triggered/cannot be disarmed - alarm audible signal
1 WCH054TSHOT171
ON (horn) and visual signal flashing (turn-signal lamps)
Vehicle perimeter alarm is not working - no alarm audible
signal (horn) and visual signal not flashing (turn-signal 2 WCH054TSHOT172
lamps)
Alarm does not trigger when one of the doors, hood or
R
3 WCH054TSHOT173
tailgate is opened
Buzzer not working properly 4 WCH054TSHOT196
Anti Theft Warning System (ATWS) LED Not Flashing 5 WCH054TSHOT197
D
For Remote Keyless Entry Initialization process please refer to BCM Special Function on page
WCH054TSHOT150
Alarm Triggered by itself/Cannot Be Disarmed – Alarm audible signal ON (Horn) and visual signal
flashing (Turn-Signal lights)
If RKE transmitter battery is Normal, and all requirements Probable Cause

are met, it is possible one of the cause as following:- • Malfunction of contact circuit/switches
• Doors, hood, trunklid or key-in contact circuit is short • Malfunction of wiring harness or connect-
to ground or
• Malfunction of the BCM • Malfunction of the BCM

All doors, hood, trunklid are properly closed and no OK GO TO 2
1 key left in key cylinder Close properly
NO
and GO TO 2

/ 148 ALARM SYSTEM

Refer Inspection
Chart for Dia-
WCH054TSHOT129
NO GO TO 3
• No. 23 (15 A) Door Unlock Power in the Panel Fuse
Box
3
Check the harness wire between the BCM, NG Replace
• C-15 and panel fuse no. 14 (10A)

T
Check the RKE transmitter (refer to WCH054TSHOT043
RKE Transmitter Key inspection procedure)
OK
NG
GO TO 5
Replace Key
AF
Check the trouble symptom OK STOP
5
NG GO TO 6
Check the Continuity of the Ground Connections: Dis- OK GO TO 7
connect connectors C-16 and C-17 and check at the
Harness Side:
R

D
6
NG Repair/ Replace
DOINC054R09135
OK: System Voltage
OK: System Voltage

ALARM SYSTEM / 149

7
• C-15,C-16, C-17 NG Repair/Replace
8
• E-01, E-04, E-06, E-09 NG Repair/Replace
Check the harness wire between the door switches (E- OK GO TO 10
9 01, E-04, E-06, E-09) and BCM, C-15 NG Repair/Replace
10
• G-03, A-34 NG Repair/Replace
Check the harness wire between the trunklid switch, OK GO TO 12
11 hood switch and BCM, C-15 NG Repair/Replace
OK GO TO 13
NG Control Module
(BCM)
T YES
Refer Inspection
Chart for Dia-
gnosis Trouble
AF
Are any of the BCM's Diagnosis Trouble Codes dis-
13 Codes on page
played?
WCH054TSHOT129
NO STOP

R
Vehicle Perimeter Alarm is Not Working – no alarm audible signal (Horn) and visual signal not flashing
(Turn-Signal lights)
The probably cause may Probable Cause
D
• No signal received by BCM • Malfunction of Horn/Turn-signal lights

• Defective horn/turn-signal lights • Malfunction of harness wire/connector/switches

Check the following system: OK GO TO 2
• Horn (refer to WCH054TSHOT135 Horn inspec-
tion)
1
• Turn-Signal and Hazard lights (refer to NG Repair/Replace
WCH054TSHOT204 Turn-Signal and Hazard in-
spection)
Refer Inspection Chart for

Are any of the BCM's Diagnosis Trouble Codes Diagnosis Trouble Codes
YES
2 displayed? on page
WCH054TSHOT129
NO GO TO 3

/ 150 ALARM SYSTEM

• No. 14 (10 A) Ignition 1-BCM in the Panel Fuse
Box
• No. 23 (15 A) Door Unlock Power in the Panel
Fuse Box
• No. 18 (15 A) Door Lock Power in the Panel
3
Fuse Box NG Replace
Check the harness wire between the BCM,
Check the Continuity of the Ground Connections: OK GO TO 5

Disconnect connectors C-16 and C-17 and check
T
(a) Check Voltage between connector C-17 Pin
No. 7 (Door Lock Power) and
AF
R
4
NG Repair/ Replace
D
DOINC054R09135
OK: System Voltage
OK: System Voltage

5
Check the harness wire between OK GO TO 7
• Horn, A-38 and BCM, C-17
6
• Turn-Signals (A-32, A-43, G-09, G-10) and BCM, NG Repair/Replace
C-16

ALARM SYSTEM / 151

Check the harness wire between panel fuse, C- OK GO TO 8
18 and
7 • BCM, C-16 (Turn-Signal Power) NG Repair/Replace
• BCM, C-17 (Horn Power)
OK GO TO 9
8 Check the trouble symptom Replace Body Control
NG
Module (BCM)
Refer Inspection Chart for
Diagnosis Trouble Codes
9 on page
NO STOP
Alarm does not rigger when one or more of the doors or hood or tailgate are Opened
T
One of the following may the cause Probable Cause
• No signal from or to BCM from RKE transmitter • Malfunction of RKE transmitter
• Open circuit between the BCM and the related contact • Malfunction of connectors/harness
AF
switches wire/contact switch

Check the RKE transmitter OK GO TO 2
R
1 (refer to the RKE section on page WCH054TSHOT043 NG Repair/ Replace

)
Refer Inspection
D
Chart for Dia-

WCH054TSHOT129
NO GO TO 3
Box
3
Check the harness wire between the BCM, NG Replace


/ 152 ALARM SYSTEM

Harness Side:
4
NG Repair/ Replace
DOINC054R09135
T
OK: System Voltage
AF
OK: System Voltage

R
5
6 • E-01, E-04, E-06, E-09
D
NG Repair/Replace
Check the harness wire between BCM, C-15 and all OK GO TO 8
doors contact switch;
7
• E-01, E-04, E-06, E-09 NG Repair/Replace
Check the harness wire between BCM, C-15 and hood OK GO TO 9

8 switch;
• A-34 NG Repair/Replace
Check the harness wire between BCM, C-15 and tailgate OK GO TO 10

switch;
9
• G-21 NG Repair/Replace
OK GO TO 11
NG Control Module
(BCM)

ALARM SYSTEM / 153

Refer Inspection
Chart for Dia-
11 Codes on page
played?
WCH054TSHOT129
NO STOP
Buzzer not working properly

• open circuit or short circuit
Buzzer circuit failure • malfunction of the wiring harness/connectors
• malfunction of the chirp buzzer

Plug in the PADT-07 Diagnostic Tool and Go to the OK GO TO 6
Dynamic Data Display Tab (refer WCH054TSHOT128)
T
For Buzzer circuit failure:
• Check the State of the Dynamic Data on the Dynamic
Data Display Tab:
AF
1 • Check the Buzzer Function by:
• Arming/Disarming the Alarm system via the RKE NG GO TO 2
Transmitter Key
Buzzer Output
ON (Arm/Disarm-Ignition OFF)
OFF (Ignition OFF)
R

D
Box
2 • No. 20 (15A) Alarm Horn Power in the Panel Fuse Box NG Repair/ Replace

/ 154 ALARM SYSTEM

Check the BCM Connectors No. C15, C16 and C17 for OK GO TO 4
proper mating
Check the Continuity of the Ground Connections: Dis-
Harness Side:
3
NG Repair/ Replace
T DOINC054R09135
AF
OK: System Voltage
R
OK: System Voltage
Disconnect the BCM Connectors No. C15 and check at OK GO TO 5

the Harness Side:
D
4
NG Repair/ Replace
DOINC054R09156
Check Voltage between BCM Connector No. C 17 Pin
No. 1(Alarm Horn Power) and
• BCM Connector No. C 17 Pin No. 8 (Ground Power)

ALARM SYSTEM / 155

OK GO TO 6
5
NG Repair/ Replace
DOINC054R09158
Check Voltage between BCM Connector No. C 15 Pin
No. 13(Chirp Buzzer) and
• Body Earth
OK: System Voltage (Ignition OFF)
OK: Buzzer Chirps Continously (Ignition OFF)
and Luggage Lamp MODULE 4.3, GROUP 9)
T
(Refer Electrical Wiring Circuit Diagrams – Room Lamp
OK GO TO 7
AF
NG
Module (BCM)
Are any of the BCM's Diagnosis Trouble Codes dis- YES
7 Codes on page
played? WCH054TSHOT129
R
NO STOP

D
Anti-Theft LED Indicator Not Flashing

• open or short circuit
• malfunction of the wiring harness/connectors
Anti-Theft Indicator Relay Driver circuit failure
• malfunction of the Instrument Cluster (Meter
Combination)

Plug in the PADT-07 Diagnostic Tool and Go to the Dynamic OK GO TO 5
Data Display Tab (refer WCH054TSHOT128)
For Anti-Theft Indicator Relay Driver circuit failure:
• Check the State of the Dynamic Data on the Dynamic Data
Display Tab:
1 • Check the Anti-Theft Indicator function by:
• Arming/Disarming the Alarm system via the RKE Transmitter NG GO TO 2
Key
Anti-Theft Indicator (Relay Driver)
ON (Arm/Disarm-Ignition OFF)
OFF (Ignition OFF)

/ 156 ALARM SYSTEM

• No. 23 (15 A) Door Unlock Power in the Panel Fuse Box
2 • No. 9 (10 A) Meter Combi in the Panel Fuse Box Repair/ Re-
NG
Check the harness wire between the BCM, place
mating
Lock Power) and
T
AF
3 Repair/ Re-
NG
place
R
DOINC054R09135
D

OK: System Voltage
1- BCM) and
OK: System Voltage

ALARM SYSTEM / 157

Disconnect the BCM Connectors No. C15 and check at the OK GO TO 5
Harness Side:
4 Repair/ Re-
NG
place
DOINC054R09158
(a) Check Voltage between BCM Connector No. C 15 Pin No.
26(Anti-Theft Indicator) and
• Body Earth
OK: System Voltage (Ignition OFF)
OK: Anti-Theft Indicator ON (Ignition OFF)
T
(b) Check the Instrument Cluster (Meter Combination) and
AF
Replace if necessary
OK GO TO 6
NG Control Mod-
ule (BCM)
Refer Inspec-
R
tion Chart for

Diagnosis
YES
on page
D
WCH054TSHOT129
NO STOP
Diagnosis Code
Diagnosis Item Reference page
No.
Front Left Door contact circuit fail-
B1319 WCH054TSHOT160
ure
Front Right Door contact circuit
failure
Rear Right Door contact circuit
failure
Rear Left Door contact circuit fail-
ure
B1331 Trunk contact circuit failure WCH054TSHOT164
B1519 Hood contact circuit failure WCH054TSHOT165
B1093 Key–In Switch circuit failure WCH054TSHOT166

/ 158 ALARM SYSTEM
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1319 : Front Left Door WCH054TSHOT11032
WARNING
Fault Codes Diagnosis Item Probable Cause

• short circuit to ground
B1319 Front Left door contact circuit failure
ors
• malfunction of the contact switch
Check the Front Left Door Contact switch function OK GO TO 5
• by opening the front left door.
• FRONT LEFT DOOR is ajar?
1
• Check the dynamic data display : Front Left Door Ajar NG GO TO 2
YES (Door Open)
NO (Door Closed)
Check Fuses:
T
OK GO TO 3
AF
2 • No. 18 (15 A) Door Lock Power in the Panel Fuse Box Replace and GO
NG
• No. 23 (15 A) Door Unlock Power in the Panel Fuse TO 3
Box
R
D

ALARM SYSTEM / 159

Harness Side:
Repair the af-

3 fected connect-
NG
ors and/or the
wiring harness
DOINC054R09135
T
OK: System Voltage
AF
OK: System Voltage
Check the following connectors for proper mating and OK GO TO 5

R
4 condition
E-09, C-03, C-15, C-17 NG Repair/ Replace
OK GO TO 10
5 Check trouble symptoms
D
NG GO TO 6
OK GO TO 7
6
NG Repair/ Replace
DOINC054R09246
Disconnect BCM Connector C-15 and check Continuity
between
• C-15 Pin No. 10 and Body Earth
Check the wire harness between BCM, C-17 and Panel OK GO TO 8
7
Fuse box connector, C-18 NG Repair/ Replace

/ 160 ALARM SYSTEM

Check the wire harness between BCM Connector , C- OK GO TO 9
8
15 Pin No. 10 and Front Left Door Switch, E-09 NG Repair/ Replace
OK GO TO 10
NG Control Module
(BCM)
Refer Inspection
Chart for Dia-
10 Codes on page
played?
WCH054TSHOT129
NO STOP
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1327 : Front Right Door WCH054TSHOT11033
WARNING
Fault Codes Diagnosis Item
T Probable Cause
AF
B1327 Front Right door contact circuit failure
ors
Check the Front Right Door Contact switch function OK GO TO 5
• by opening the front right door.
R
• FRONT RIGHT DOOR is ajar?

1 • Check the dynamic data display : Front Right Door
NG GO TO 2
D
Ajar
YES (Door Open)
NO (Door Closed)
NG Replace
Box

ALARM SYSTEM / 161

Harness Side:
Repair the af-

3 fected connect-
NG
ors and/or the
wiring harness
DOINC054R09135
T
OK: System Voltage
AF
OK: System Voltage

R
4 condition
E-01, C-13, C-15, C-17 NG Repair/Replace
OK GO TO 10
D
NG GO TO 6
OK GO TO 7
6
NG Repair/ Replace
DOINC054R09247
between
7

/ 162 ALARM SYSTEM

Check the wire harness between BCM, C-15 Pin No. 39 OK GO TO 9
8
and Front Right Door Switch, E-01 NG Repair/Replace
OK GO TO 10
NG Control Module
(BCM)
Refer Inspection
Chart for Dia-
10 Codes on page
played?
WCH054TSHOT129
NO STOP
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1335 : Rear Right Door WCH054TSHOT11034
WARNING
T Probable Cause
AF
B1335 Rear Right Door contact circuit failure
ors
Check the Rear Right Door Contact switch function OK GO TO 5
• by opening the rear right door.
R
• REAR RIGHT DOOR is ajar?

1 • Check the dynamic data display : Rear Right Door
NG GO TO 2
D
Ajar
YES (Door Open)
NO (Door Closed)
NG Replace
Box

ALARM SYSTEM / 163

Check the Continuity of the Ground Connections: Dis- OK GO TO 4
Harness Side:
Repair the af-

3 fected connect-
NG
ors and/or the
wiring harness

T DOINC054R09135
AF
OK: System Voltage
OK: System Voltage
R

4 condition
OK GO TO 10
D

NG GO TO 6
OK GO TO 7
6
NG Repair/ Replace
DOINC054R09248
between

/ 164 ALARM SYSTEM

7
8
and Rear Right Door Switch, E-04 NG Repair/Replace
OK GO TO 10
NG Control Module
(BCM)
Refer Inspection
Chart for Dia-
10 Codes on page
played?
WCH054TSHOT129
NO STOP
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1571 : Rear Left Door WCH054TSHOT11035
WARNING
T
AF
Fault Codes Diagnosis Item Probable Cause
B1571 Rear Left door contact circuit failure
ors
R
Check the Rear Left Door Contact switch function OK GO TO 5

• by opening the rear left door.
D
• REAR LEFT DOOR is ajar?

1
• Check the dynamic data display : Rear Left Door Ajar NG GO TO 2
YES (Door Open – Ignition : ON)
NO (Door Closed – Ignition : ON)
NG Replace
Box

ALARM SYSTEM / 165

Harness Side:
Repair the af-

3 fected connect-
NG
ors and/or the
wiring harness
DOINC054R09135
T
OK: System Voltage
AF
OK: System Voltage

R
4 condition
OK GO TO 10
D
NG GO TO 6
OK GO TO 7
6
NG Repair/ Replace
DOINC054R09249
between
7
Fuse, C-18 NG Repair/ Replace

/ 166 ALARM SYSTEM

8
and Rear Left Door Switch, E-06 NG Repair/Replace
OK GO TO 10
NG Control Module
(BCM)
Refer Inspection
Chart for Dia-
10 Codes on page
played?
WCH054TSHOT129
NO STOP
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1331 : Tailgate WCH054TSHOT11036
WARNING
T Probable Cause
AF
B1331 Tailgate contact circuit failure
ors
Check the Tailgate Contact switch function OK GO TO 5
• by opening the trunk lid.
R
• Tailgate is ajar?
1 • Check the dynamic data display : Decklid, Tailgate
NG GO TO 2
D
Ajar
YES (Trunk Lid Open)
NO (Trunk Lid Closed)
NG Replace
Box

ALARM SYSTEM / 167

Harness Side:
Repair the af-

3 fected connect-
NG
ors and/or the
wiring harness
DOINC054R09135
T
OK: System Voltage
AF
OK: System Voltage

R
condition
4
G-03, G-07, G-08, C-13, C-15, C-16, C-17, G-05, G-17, G- NG Repair/Replace
21
OK GO TO 9
D

NG GO TO 6
OK GO TO 7
6
NG Repair/ Replace
DOINC054R09250
between

/ 168 ALARM SYSTEM

7
and Tailgate Latch Actuator, G-21 NG Repair/ Replace
OK GO TO 9
NG Control Module
(BCM)
Refer Inspection
Chart for Dia-
9 Codes on page
played?
WCH054TSHOT129
NO STOP
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1519 : Hood WCH054TSHOT11037
WARNING
T Probable Cause
AF
B1519 Hood contact circuit failure
ors
Check the Hood Contact switch function OK GO TO 5
• by opening the hood.
R
• HOOD is ajar?
1
• Check the dynamic data display : HOOD Ajar NG GO TO 2
D
YES (Hood Open)

NO (Hood Closed)
NG Replace
Box

ALARM SYSTEM / 169

Harness Side:
Repair the af-

3 fected connect-
NG
ors and/or the
wiring harness
DOINC054R09135
T
OK: System Voltage
AF
OK: System Voltage

R
4 condition
A-06, A-26, A-30, A-34, C-02, C-15, C-18 NG Repair/Replace
OK GO TO 10
5 Check the trouble symptoms
D
NG GO TO 6
OK GO TO 7
6
NG Repair/ Replace
DOINC054R09251
between
7
Fuse box, C-18 NG Repair/ Replace

/ 170 ALARM SYSTEM

8
and Hood Switch, A-34 NG Repair/Replace
OK GO TO 10
NG Control Module
(BCM)
Refer Inspection
Chart for Dia-
10 Codes on page
played?
WCH054TSHOT129
NO STOP
INSPECTION PROCEDURE FOR DIAGNOSIS CODE NO. B1093 : Key–In Switch WCH054TSHOT11038
WARNING
T Probable Cause
AF
B1093 Key–In Switch circuit failure
ors
R

NG GO TO 2
D
Box

ALARM SYSTEM / 171

Harness Side:
Repair the af-

2 fected connect-
NG
ors and/or the
wiring harness
DOINC054R09135
T
OK: System Voltage
AF
OK: System Voltage

R
3 condition
C-15, C-16, C-17, C-18, C-19, D-16 NG Repair/Replace
4 condition
D
A-06, A-26, A-30, A-34, C-02, C-15, C-18 NG Repair/Replace

OK GO TO 9
NG GO TO 6

/ 172 IMMOBILIZER SYSTEM

OK GO TO 7
6
NG Repair/ Replace
DOINC054R09252
between
OK : Continuity (Key Not in Key Cylinder)
OK : No Continuity (Key in Key Cylinder)
In Switch, repair if necessary

T
Check the wire harness between BCM, C-15 and Key- OK GO TO 8
AF
Disconnect connector C-15 and measure at harness side
7 • Continuity between C-15 Pin No. 4 and Body Earth. NG Repair/ Replace
OK : Continuity (Key Not in Key Cylinder)
OK : No Continuity (Key in Key Cylinder)
R
OK GO TO 9
Check the wire harness between BCM, C-15 and Panel Replace Body
8
Fuse box, C-18 NG Control Module
(BCM)
D
Refer Inspection
Chart for Dia-
9 Codes on page
played?
WCH054TSHOT129
NO STOP
IMMOBILIZER SYSTEM WCH054GINFO11008
INTRODUCTION
The PROTON immobilizer system is designed as to provide additional theft prevention mechanism
system by preventing unauthorized engine start for the MPI gasoline engine. Once the code coincide
or matched, the EMS will enable the vehicle to be started in normal way. The immobilizer system
consists of the ignition key, the key ring antenna and an integrated immobilizer circuits inside the
ECU. The ignition key has a transponder which transmits data to the transceiver by modulating the
amplitude of the electromagnetic field and receives data commands in a similar way. The system
prevent the engine from being started deviously to protect the vehicle from theft.
The key ring antenna is installed differently based on vehicle variant

IMMOBILIZER SYSTEM / 173
Variant Location
Standard (vehicle without start/stop button) fitted to steering lock
H-line ( vehicle with start/stop button) fitted to bracket on I/P
DOIQC054R11045
The operation is as follows.

1. As key is inserted inside the key fob folder, transponder on PCB transmitter will always have
combination will be displaying warning.
T
communication with key ring antenna, if the key is removed, EMS shall flag this on CAN and meter
2. Whist operation starts, the key ring antenna will generate magnetic field at 125KHz which charge
AF
the transponder. The key ring antenna will then carry the modulated signal between transponder
and immobilizer based station.
3. Key ring antenna is connected to EMS via synchronous serial link.
4. EMS as the master of the serial link will perform encrypted authentication with transponder
through key ring antenna, using the same encryption algorithm that is implemented in the
transponder.
If the ignition key is lost or another ignition key is added, the ID code can be registered or erased by
R
using the PADT-II with maximum of 5 keys coded at one time. (refer to group 11A Engine- PADT-II)
SPECIFICATION
D
ITEM STANDARD VALUE

Nominal voltage 13.5 V
Operating voltage 6.5 V — 16 V
Over voltage protection 26 V
Reverse voltage protection 15 V
Active current 0.15 A
Quiescent current < 0.001 A
Serial interface bit rates 30 kbps
LF communication frequency 125000 Hz

Wireless And Serial Cable Diagnostic

EZT 0038 PADT-07 Immobilizer system check
EZT 0016 PADT-07, VCI (Diagnosis displayed using
the PADT-07) Registration
EZT 0029 Cable-OBD II
of the ID code
EZT 0026 Trigger Button
Computer
DOIIC11AR07018
CHECK AT KEY RING ANTENNA WCH054SPROC11025
T
AF
DOIQC054R11046
R
D
DOIQC054R11052
Terminal Signal Checking requirements Standard value

1 - - -
2 - - -
Key ring antenna signal to
3 ECU (SCLK- Serial link syn- Ignition switch : OFF 0V
chronizer)
Key ring antenna signal to
4 Ignition switch : OFF 0V
ECU (SDATA- READ/WRITE)
Key ring antenna power
5 Ignition switch : OFF 0V
supply

Terminal Signal Checking requirements Standard value

Key ring antenna power
6 Ignition switch : ON System voltage
supply
7 - - -
8 - - -
9 - - -
10 - - -
11 - - -
12 - - -
T
AF
R
D

SPECIAL FUNCTION MENU WCH054SPROC11026
IMMOBILIZER CODING — 1] KEY ID REGISTER
T
AF
R
DOIGE11AR08018
ECU EMS 700 / Special Function

D
2] Immobilizer Coding 1] Key ID Register Test Condition Ignition On

1. For KEY ID REGISTER:
The security code needed to perform “ KEY
ID REGISTER ”.

T
AF
DOIGE11AR08019
R
2. Please wait.
Key transponder is registering to control unit.
D

T
AF
DOIGE11AR08020
R
3. Key transponder registered successfully.

D

IMMOBILIZER CODING — 2] CLEAR KEYS
T
AF
R
DOIGE11AR08022
1. For CLEAR KEYS:

All key transponders registered in control
D
unit is in progress to be cleared.

T
AF
DOIGE11AR08023
R
2. Key transponders in control unit has been

cleared successfully.
D
Fault Code No. Fault Reference Page

P1570 Communication with transponder missing
WCH054TSHOT148
P1570 Start attempt thus immobilizer
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code No. P1570: Transponder Communication System Probable Cause
• Malfunction of the transponder
The code of the transponder is not sent to the ECU imme- • Malfunction of the ignition key ring
diately after the ignition switch is turned to the ON position antenna

T
AF
R
D
DOIMC054R08004
INSPECTION CHART FOR TROUBLE SYMPTOMS WCH054TSHOT11040
Trouble Symptoms Inspection Procedure No.

Communication with PADT-07 is impossible 1
Engine crank once but no initial combustion 2
Malfunction of ECU power supply and earth circuit 3
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
INSPECTION PROCEDURE 1 : Communication With PADT-07 Is Impossible
Communication with PADT-07 is impossible Probable cause
• The cause is probably that an open circuit • Malfunction of diagnosis line
or short circuit of the diagnosis line or the • Open circuit or short circuit of harness between
ECU is not functioning ECU and diagnosis connector
• Check the key ring antenna
• Malfunction of the ECU

Communication with PADT-07 is impossible Probable cause
T
AF
R
DOINC054R09078
INSPECTION PROCEDURES 2 : Engine Does Not Start (Cranking But No Initial Combustion)
Engine does not start (Cranking but no initial combustion). Probable cause
D
• If the fuel injections are not operating, there might be a problem • Malfunction key ring an-
with the ECU-engine control unit system in addition to a malfunction tenna
of the immobilizer system. It is normal for this to occur if an attempt • Open circuit or short cir-
is made to start the engine using a key that can't be recognized by cuit of harness between
ECU. key ring antenna and
ECU
• Malfunction of the -ECU

Engine does not start (Cranking but no initial combustion). Probable cause
T
AF
R
DOINC054R09079
INSPECTION PROCEDURE 3 : Malfunction of The Immobilizer-ECU Power Source and Earth Circuit
Malfunction of the immobilizer-ECU power source and earth circuit
D

/ 184 REMOTE KEYLESS ENTRY SYSTEM (RKE)
T
AF
R
DOINC054R09080
D
REMOTE KEYLESS ENTRY SYSTEM (RKE) WCH054GINFO11009
GENERAL INFORMATION
TRANSMITTER KEY
The RKE Transmitter Key has three buttons: a lock button, an unlock button and a panic button, the
detail function is described in the following table:
Figure Symbol Buttons Possible Operations

Central lock, vehicle
1 Lock
search
Central unlock, unlock
2 Unlock
driver door only
3 Panic Panic Alarm
Mute alarm or DDU/CDU
Lock + Un-
according to BCM EEP-
lock (simul-
1+2 ROM configuration, de-
taneous
fault is DDU/CDU
press)
DOINW003R09007 toggle/switch.

REMOTE KEYLESS ENTRY SYSTEM (RKE) / 185
After a key fob button is pressed, the transmitter key sends a Radio Frequency (RF) telegram wave.
The "RF reception" functionality in BCM decodes the received bit stream telegram wave pattern. and
provides it to the RKE functionality. The RKE functionality is responsible for providing suitable strategies
to ensure the proper distribution of the user commands. The commands from the key fob could be
translated into:
• Central Door Lock (Lock/Unlock action)
• Alarm Arm/Disarm
• Panic Alarm
• Remote Keyless Entry (RKE) Initialization (Key Learning)
T
AF
R
D
DOINC054R09113
The Central Door Locking, Panic Alarm and other RKE operations will be described in detail in the
Alarm System (ATWS) and Central Door Locking sections.
WCH054TSHOT150

LITHIUM Coin Cell Type CR2032
Battery type
DC 3 V
Operating voltage range DC 2 V ~ 3.5 V
-20 °C (-4 °F) to 60 °C (140 °F) (Lim-
Operating temp. range
Transmitter key ited by battery)
Storage temp. range -40 °C (-40 °F) to 85 °C (185 °F)
Max Working Current < 2.6 mA
Transmitting frequency 433.92 ± 0.1 MHz
Quiscence Current < 0.0015 mA
Tools Number Name Use
EZT0038
T
PADT– 07 (Set of Diagnostic
Proton Advance Diagnostic
Tool-07)
For vehicle diagnosis,
RKE troubleshoot-
ing/BCM troubleshoot-
AF
ing
DOIIC11AR07018

R
Inspection proced-
ure no.
Transmitter key cannot activate/deactivate the alarm
1 WCH054TSHOT043
D
system or the central door locking system

Remote Illuminated Entry (Approach Lamps) function
is not working (However, the room lamp operates nor- 2 WCH054TSHOT044
mally when the doors/ tailgate are opened and closed)
Driver Door only Unlocking with Mute Alarm (DDU) is
3 WCH054TSHOT045
not working
Transmitter can activate or deactivate the alarm system
or central door locking system while the key is in the 4 WCH054TSHOT046
key cylinder with “ON” position
Remote Keyless Entry Initialization is not possible (new
5 WCH054TSHOT047
transmitter key cannot be registered to BCM)
Control distance of the transmitter become nearer (less
6 WCH054TSHOT048
than 10 m (32.81 ft))
Difficult to activate or deactivate the alarm system or
the central door locking system in certain areas with 7 WCH054TSHOT049
the transmitter key
WCH054TSHOT150

Transmitter Key cannot activate or deactivate the Alarm System or the Central Door Locking System
Probable Cause
• RKE Transmitter Key Battery Low
• Malfunction of the RKE Transmitter Key
The cause may be a malfunction of the transmitter, the • Malfunction of the BCM
receiver or the lock and unlock signals are not being sent
to the BCM • Malfunction of the contact switches
connectors
• Malfunction of the key cyclinder switch

Replace the RKE Trans-
Is the RKE Transmitter Key Battery Low warning YES mitter Key Battery
1 displayed on the Combination Meter? refer page
NO GO TO 2
2 displayed?
T
Codes on page
AF
WCH054TSHOT129
NO GO TO 3
Does the Central Door Locking function work YES GO TO 4
3 properly when activated via the Lock/ Unlock Check the Central Door
switch on the Driver Door? NO Locking System on
page
R
• No. 14 (10 A) Ignition-1 BCM in the Panel Fuse
Box
D

Fuse Box
Box NG
GO TO 5
Conduct the Remote Keyless Entry Initialization OK GO TO 16

5 process again and check whether the RKE Trans-
(1) NG GO TO 6
mitter Key is working.
Check the following connectors for proper mating OK GO TO 7
and connection:
6
• C-13, C-15,C-16, C-17, C-18 NG Repair/Replace



wiring harness

T DOINC054R09135
AF
OK: System Voltage
R
OK: System Voltage
Check all the door contact switches by: OK GO TO 10

D

NG
Check the Continuity of the Door Contact Switch,
10 • C-02, C-03, C-13, C-15, C-16, C-17

NG Repair/Replace
• E-01, E-04, E-06, E-09
Check continuity of the harness wire between the OK GO TO 12

11 door switch and BCM, C-15 NG Repair/Replace
Check the Ignition Key cylinder switch continuity OK GO TO 13
12 (refer to GRP 54-IGNITION SWITCH) NG Repair/Replace
Check the following connectors OK GO TO 14
13 • D-16, C-15 NG Repair/Replace


14 C-16
NG Repair
Replace the Transmitter Key and check the trouble OK GO TO 16

15
16 Codes on page
NO STOP
NOTE:
(1) This process is required to either a new or replacement RKE Transmitter Key to the BCM
Remote Illuminated Entry (Approach Lamps) function is not working (However, the room lamp
operates normally when the doors/ tailgate are opened and closed)
If the room lamp operates normally when the doors are
TProbable Cause
opened and closed, and if the doors can be locked and • Malfunction of contact circuit/switches
AF
unlocked with the Transmitter Key the cause of the • Malfunction of wiring harness or connect-
problem may be malfunction of the of the Interior or
Lighting system or a malfunction of the BCM

R
NO GO TO 2
D

YES
WCH054TSHOT129
NO GO TO 3
YES GO TO 4
Does the Central Door Locking function work Check the Central Door
3 properly when activated via the Lock/ Unlock Locking System on
switch on the Driver Door refer to ? NO
page
WCH054TSHOT186


Box
Fuse Box
Box NG
GO TO 5
Check the Interior Lighting System refer to OK GO TO 6

5
WCH054TSHOT174 NG Repair/Replace
T
and connection:
6
AF
R
D

wiring harness
DOINC054R09135
OK: System Voltage
OK: System Voltage


11 C-16
NG Repair
OK GO TO 13
NG
Module (BCM)
13 Codes on page
NO STOP
T WCH054TSHOT11044
AF
Driver Door only Unlocking with Mute Alarm (DDU) is not working
Probable Cause
The cause may be a malfunction of harness wire (open • Malfunction of the wiring harness or
circuit or short circuit) or a defective connector or a connector
malfunction of BCM
R

D

NO GO TO 2
YES
WCH054TSHOT129
NO GO TO 3
3 properly when activated via the Lock/ Unlock Check the Central Door
switch on the Driver Door? NO Locking System on
page


Box
Fuse Box
4 Box Replace the Fuse and
NG
• No. 9 (10 A) Meter Combi in the Panel Fuse Box GO TO 5
Conduct the Remote Keyless Entry Initialization OK GO TO 16

5 process again and check whether the RKE Trans-
NG GO TO 6
T
(1)
mitter Key is working.
and connection:
6
AF

R
D



wiring harness
DOINC054R09135
T
OK: System Voltage
AF
OK: System Voltage

R

NG
D

10 • C-02, C-03, C-13, C-15, C-16, C-17

NG Repair/Replace
• E-01, E-04, E-06, E-09

14 C-16
NG Repair


Replace the Transmitter Key and check the trouble OK GO TO 16
15
16 Codes on page
NO STOP
NOTE:
(1) This process is required to either a new or replacement RKE Transmitter Key to the BCM
Transmitter can activate or deactivate the alarm system or central door locking system while the key
is in the key cylinder with “ON” position
Probable Cause
• Key ignition cylinder switch connection
The cause may be the connection at key ignition cylinder loose
switch is loose or a malfunction of the wiring harness or
• Malfunction of wiring harness or connect-
T
connector or malfunction of the BCM
or
AF
YES
WCH054TSHOT129
NO GO TO 2
R
Box
D

Fuse Box
Box NG
GO TO 3

and connection:
3




wiring harness
DOINC054R09135
T
OK: System Voltage
AF
OK: System Voltage

6
R
(refer to GRP 54-IGNITION SWITCH) NG Repair/Replace

D

8 C-16
NG Repair
OK GO TO 10
NG Replace BCM
10 Codes on page
NO STOP

Remote Keyless Entry Initialization is not possible (new transmitter key cannot be registered to BCM)
Probable Cause
• Malfunction of the Transmitter Key
The cause may be a malfunction of wiring harness or
connector, malfunction of the diagnostic connector, a • Malfunction of the wiring harness or
faulty Transmitter Key, a malfunction of the Diagnostic connector
Tool or a malfunction of the BCM • Malfunction of PADT-07

NO GO TO 2
YES
Check Fuses:
T NO
OK
WCH054TSHOT129
GO TO 3
GO TO 4
AF
• No. 14 (10 A) BCM in the Panel Fuse Box
Fuse Box
3 Box Replace the Fuse and
R
NG
Check the harness wire between the BCM, GO TO 4

D


and connection:
4




wiring harness
DOINC054R09135
T
OK: System Voltage
AF
OK: System Voltage
Disconnect the BCM connectorC-15 and Diagnostic OK GO TO 8

R
connector D-11 and measure at the harness side

• Continuity between C-15 pin no. 40 and D-11
pin no. 14CAN Low Repair the affected
7
D
• Continuity between C-15 pin no. 30 and D-11 NG connectors and/or the
pin no. 6 CAN High wiring harness
OK: Continuity OK
OK GO TO 9
Can the PADT-07 communicate with other sys- Refer Power Supply
8 tems? NG and CAN Communica-
tion Systems on page
11 C-16
NG Repair


OK GO TO 13
NG Replace BCM
13 Codes on page
NO STOP
Control distance of the transmitter become nearer (less than 10 m (32.81 ft))
Probable Cause Remedy
The cause may be The solution is as follows:
1. The battery of the Transmitter Key is weak. 1. Replace the battery of the Transmitter Key.
2. Strong interference caused by excessive Radio 2. Drive the vehicle away from the particular spot
Frequency activity in a particular area e.g. and retest the control distance.
mobile telephone is in operation beside the 3. Relocate the audio devices away from the
T
vehicle alarm control unit.
3. Strong harmonic interference e.g. audio
devices like a high performance car speaker is
AF
installed near the Alarm control unit
Difficult to activate or deactivate the alarm system or the central door locking system in certain areas
with the transmitter key
Probable Cause Remedy
R
• Strong inteference caused by excessive Radio • The interference is temporary and only while
Frequency activity in a particular area the vehicle is in that area, drive away the vehicle
from that particular area.
D

CENTRAL DOOR LOCKING / 199
HOW TO REPLACE A BATTERY OF THE

TRANSMITTER KEY.
1. Remove the screw to dismantle the transmit-
ter key, then remove the battery from the
transmitter.
2. Install the new battery with its (+) side facing
downwards.
Battery required for replacement:
LITHIUM Coin Cell type battery CR2032 DC
3V
3. Insert the claw carefully so that the o-ring is
not displaced. Then assemble the transmitter.
4. Check whether the keyless entry system op-
erates normally.
NOTE
(1) Do not let water or dust stick to the in-
side of the transmitter when it is open.
Also, do not touch the precision electron-
T ic device.
(2) If the O-ring is displaced during the as-
sembly of the transmitter, water and or
AF
dust can penetrate into the transmitter
key and cause a malfunction.
DOINC054R09244 Symbol Description
A Transponder
R
CENTRAL DOOR LOCKING WCH054GINFO11010
GENERAL INFORMATION
CENTRAL DOOR LOCKING FUNCTIONS
D
The BCM's central locking function provides the following features:

• Remote Central Lock / Unlock
• Remote Central Unlock Driver Door only
• Switching/Toggling between the Remote Central Lock / Unlock and Driver Door Only Unlock
• Key Cylinder Central Lock / Unlock
• Driver side button Central Lock / Unlock
• Reverse Unlock , if any of front doors is ajar
• Overload protection of 4 doors latch motors
• Overload protection of tailgate latch motors
• Auto relock
• Speed/Drive away locking
• Crash unlock
• Ignition off unlock

/ 200 CENTRAL DOOR LOCKING
T
AF
R
DOINC054R09101
Interior button/Key Cylinder on driver door latch Central Lock/Unlock

When Central Lock button is pressed or key in key cylinder is turned to Lock position,
D
• if both front left door and front right door are closed,
• all 4 doors are locked.
If either front left door or front right door is ajar, all 4 doors are reverse unlocked. After central lock,
the interior light will be off with fade out.
When Central Unlock button is pressed or key in key Cylinder is turned to Unlock position,
• all 4 doors are unlocked so they can be opened from the outside or the inside of the vehicle.
• Interior central unlock can be executed only when vehicle is in disarmed state.
• After central unlock, the interior light will be on with fade in.
Driver Door ONLY Unlock and switching with RC_LOCK+RC_UNLOCK
If current CDL unlocking mode is DDU, and the doors are locked, after first central unlock request,
• the driver door will be unlocked while other 3 doors are still locked.
• After second central unlock request other 3 doors will be central unlocked.
• Press down the remote transmitter Lock and Unlock buttons simultaneously for 2 s to switch/toggle
between CDU and DDU mode. The flasher will work for 2 times for acknowledgement.
Reverse Unlock
When any valid central lock request is received,
• if driver door or passenger door is ajar and vehicle is unlocked,

• central lock will be activated first and then all doors are unlocked immediately.
Remote Central Lock/Unlock or Panic Alarm (configurable)
The remote function is active only when ignition is OFF and key is not in the ignition cylinder.
Remote Lock
After remote transmitter lock command is received,
• the interior light will be off with fade out.
• The turn lights will flash one time and the buzzer will chirp one time for domestic variant.
Lock flasher acknowledge sequence is described in the Turn Signal Flashers section.
Lock buzzer acknowledge sequence is described in the Driver Information Warning section.
Remote Unlock
When unlock button of remote transmitter is pressed,
• all 4 doors are unlocked so they can be opened from the outside or the inside of the vehicle.
After remote unlock command,
• the interior light will be on with fade in.
• The position lamp will be on for 30 seconds.
• The turn lights will flash two times, and
• for domestic variant, the buzzer will chirp twice.
This 30 seconds time is the same configurable byte as auto relocking time in BCM nonvolatile memory.
T
Unlock flasher acknowledge sequence is described in Turn Signal Flashers section.
Unlock buzzer acknowledge sequence is described in Driver Information Warning section.
AF
Remote Panic Alarm
If the 3rd button of remote transmitter is configured as Panic Alarm, when panic button is pressed
down for longer than 500ms, the Panic Alarm will be activated as described in ATWS section.
If the 3rd button of remote transmitter is configured as tailgate Release, when lock button of remote
transmitter is pressed longer than 2 seconds, the panic will also be activated.
R
• The buzzer will chirp once for Panic Alarm for domestic variant.
Vehicle Search
When ignition is OFF and key is not inserted in ignition cylinder, and vehicle is central locked, If the
D
lock button of the remote transmitter is pressed twice time successively within interval time of 500ms,
the vehicle search will be activated. After vehicle search command execution,
• turn lights and buzzer will work for three times by default for acknowledgement.
Number of buzzer chirps for vehicle search can be configured in BCM EEPROM memory. By default it
is 3.
Vehicle search flasher acknowledge sequence is described in Turn Signal Flashers section. Vehicle
search buzzer acknowledge sequence is described in Driver Information Warning section.
Remote command inhibit
Remote commands except disarm from remote transmitter are inhibited when ignition is on or key
is in ignition cylinder.
NOTE: Remote Unlock request to disarm BCM from alarming state shall always be valid even when
ignition is on or key is in ignition cylinder.
Speed/Drive away locking
The speed locking feature automatically central locks the vehicle if
• Ignition is ON and
• vehicle speed is above 20km/h for 100ms.
Speed locking reset condition is:

• Ignition is OFF for at least 200ms or

• any door open and close again.
Speed lock will be triggered only once until reset condition is met. This 20km/h speed threshold is
configurable in BCM EEPROM memory.
Auto relocking
The auto relocking feature automatically central locks the vehicle after 30s following an unlock request
from remote transmitter if no door is opened and the ignition remain in the OFF position.
The vehicle will be rearmed after auto relock. After auto relock,
• the interior light will be illuminated by remote unlock or
• vehicle search will be turned off immediately.
After auto relock,
• turn lights will flash one time, the flash sequence is same as remote lock flasher sequence.
This 30 seconds time is configurable in BCM EEPROM memory.
Crash unlocking
The crash unlocking feature automatically central unlocks the vehicle
• immediately after crash detection from a hardwired signal line.
Crash active signal sequence is described in BCM load specification. Crash unlock event is saved to
T
BCM EEPROM memory to make sure unlock will be executed successfully.
• 2 unlock actions will be performed by BCM as Crash unlock sequence with interval of 3 seconds.
After crash unlock, hazard sequence will be run. Crash Hazard sequence is the same as hazard flasher
AF
sequence.
IGN OFF and key out auto unlock
The ignition off unlock feature automatically central unlocks the vehicle after
• ignition off and
• key is pulled out from the ignition cylinder.
R
Key out as a trigger condition can be configurable in BCM EEPROM memory. By default, Key out is
configured as a trigger condition.
IGN OFF auto unlock reset condition is:
D
• Ignition ON.
IGN OFF auto unlock will be trigger once until reset condition is met.

OVERHEATING PROTECTION
T
AF
R
DOINC054R09102
Over heating protection for all door latches and tailgate latch
The Central Door Locking function has a Fail Safe function to protect the motors from incorrect usage
D
or abuse, which can eventually lead to overheating and failure of the door latch motors .
Over heating protection is activated when:
• After 30 times (Configurable) successive lock or unlock action is performed and
• if the interval between two successive lock or unlock request is less than 1280 micro seconds.
Once over heating protection is activated, only
• crash unlock is allowed or
• one more unlock request can be executed,
• all of the following locking and/or unlocking requests will be blocked temporarily for 20 seconds.

Inspection proced-
ure no.
Auto unlock function not working when Ignition is 'OFF'
and the Key is taken out of the Key Cylinder
1 WCH054TSHOT192
Auto relocking function not working after 30 seconds

Inspection proced-
ure no.
Auto relocking function not working when vehicle speed
goes above 20km/h 2 WCH054TSHOT193
Central Door Lock/ Unlock function not working when activ-

ated using the Interior Lock/ Unlock button on the Drive side
Door
3 WCH054TSHOT194
Central Door Lock/ Unlock function not working when activ-
ated using the Key Cylinder on the Drive side Door
Home Safe Light function not working

(On then Off then ON the Headlamp switch again and Press 4 WCH054TSHOT195
the Lock Button)
Crash unlocking function not working in the event of a crash

and after the airbag has been deployed Refer SRS System
T
• Auto unlock function not working when Ignition is 'OFF' and the Key is taken out of the Key Cylinder
• Auto relocking function not working after 30 seconds
AF
Probable Cause
The cause may be a malfunction of thewiring harness or connectors (open or short circuit)
connectors, a malfunction of the door lock actuators or • Malfunction of the door lock actuators
door lock switch or a malfunction of the BCM switches
R

D
YES GO TO 2
Is the Remote Keyless Entry (RKE) function Refer Remote Keyless
1 working properly? Entry System (RKE) on
NO
page
WCH054TSHOT042
YES
WCH054TSHOT129
NO GO TO 3
3 properly when activated via the Lock/ Unlock Check the Door Lock
switch on the Driver Door? NO Actuators refer to MOD
1.11, Group 42


Box
4 • No. 23 (15 A) Door Unlock Power in the Panel Replace the Fuse and
Fuse Box NG
GO TO 5
• No. 18 (15 A) Door Lock Power in the Panel
Fuse Box
Check the following connectors for proper OK GO TO 6

mating and connection:
5

Disconnect the BCM connectorC-15, C-16, C-17 OK GO TO 8
and measure at the harness side
T
Measure at the BCM connectors
• Voltage betweenC-17 pin no. 7 and C-16 pin
no. 5
AF
• Voltage between C-17 pin no. 7 and C-17 pin
no. 8
OK: System Voltage
Measure at the BCM connector, C-15 NG connectors and/or the
• Disconnect the connector and measure at the wiring harness
R
harness side
• Ignition switch : ON and OFF
D

no. 8
OK: 0 Voltage (Ignition OFF)

• Opening and closing the doors one by one
and observe the door ajar signal in the Combin-
8 ation Meter Repair/Replace the
NG
Check the Continuity of the Door Contact
Switch, refer MODULE 1.1, Group 42
9 • C-02, C-03, C-13, C-15, C-16, C-17

NG Repair/Replace
• E-01, E-04, E-06, E-09
Check continuity of the harness wire between OK GO TO 11

10 the door switch and BCM, C-15 NG Repair/Replace


13 C-16
NG Repair
OK GO TO 15
NG Replace BCM
YES
WCH054TSHOT129
NO STOP
Auto relocking function not working after 30 seconds
T WCH054TSHOT11051
AF
Probable Cause
R

D
YES GO TO 2
Is the Remote Keyless Entry (RKE) function work- Refer Remote Keyless
1 ing properly? Entry System (RKE) on
NO
page
WCH054TSHOT042
YES
WCH054TSHOT129
NO GO TO 3
switch on the Driver Door? NO Actuators refer to
MOD 1.11, Group 42


Box
4 • No. 23 (15 A) Door Unlock Power in the Panel Replace the Fuse and
Fuse Box NG
GO TO 5
Box

and connection:
5

Disconnect the BCM connectorC-15, C-16, C-17 and OK GO TO 8
measure at the harness side
T
• Voltage betweenC-17 pin no. 7 and C-16 pin no.
5
AF
no. 8
OK: System Voltage
R
harness side
D

no. 8
Disconnect the BCM connectorC-15 and Diagnostic OK GO TO 9

connector D-11 and measure at the harness side
• Continuity between C-15 pin no. 40 and D-11
pin no. 14CAN Low Repair the affected
8
• Continuity between C-15 pin no. 30 and D-11 NG connectors and/or the
pin no. 6 CAN High wiring harness
OK: Continuity OK


NG
10 • C-02, C-03, C-13, C-15, C-16, C-17

NG Repair/Replace
• E-01, E-04, E-06, E-09

T
AF
14 C-16
NG Repair
OK GO TO 16
NG Replace BCM
R

YES
WCH054TSHOT129
D
NO STOP
• Central Door Lock/ Unlock function not working when activated using the Interior Lock/ Unlock
button on the Drive side Door
• Central Door Lock/ Unlock function not working when activated using the Key Cylinder on the
Drive side Door
Probable Cause


YES GO TO 2
NO
page
WCH054TSHOT042
YES
WCH054TSHOT129
NO GO TO 3
switch on the Driver Door? NO Actuators refer to
MOD 1.11, Group 42
Box
4
Fuse Box
T
NG
Replace the Fuse and
GO TO 5
AF
Box

and connection:
5
R

D

5
no. 8
OK: System Voltage
harness side
no. 8


NG
9 • C-02, C-03, C-13, C-15, C-16, C-17

NG Repair/Replace
• E-01, E-04, E-06, E-09

T
AF
13 C-16
NG Repair
OK GO TO 15
NG Replace BCM
R

YES
WCH054TSHOT129
D
NO STOP
Home Safe Light function not working
Probable Cause
connectors (open or short circuit)
The cause may be a malfunction of the wiring harness or
door lock switch, a malfunction of the Headlamp switch switches
or Bulb or a malfunction of the BCM • Malfunction of the Headlamp switch or
Bulb


YES GO TO 2
NO
page
WCH054TSHOT042
YES
WCH054TSHOT129
NO GO TO 3
YES GO TO 4
Does the Headlamp function properly when Check the Headlamp
3 switched on manually? NO refer to page
WCH054TSHOT141
Box
4
Fuse Box
T
NG
Replace the Fuse and
GO TO 5
AF
Box

and connection:
5
R

D

5
no. 8
OK: System Voltage
harness side
no. 8


NG
9 • C-02, C-03, C-13, C-15, C-16, C-17

NG Repair/Replace
• E-01, E-04, E-06, E-09

T
AF
13 C-16
NG Repair
OK GO TO 15
NG Replace BCM
R

YES
WCH054TSHOT129
D
NO STOP

Interior central unlock switch failure – short cir-
B1300
cuit to GND
Interior central lock switch circuit failure/latch
Central Door Locking System (refer to
B1310 door lock switch circuit failure – short circuit to
page WCH054TSHOT177)
GND
Latch door unlock circuit failure – short circuit
B1301
to GND
SYSTEM BLOCK DIAGRAMS WCH054TSHOT11055
The Central Door Lock/Unlock System

T
AF
DOINC054R09069
R
The Remote Keyless Entry (RKE) and the Alarm System – Anti-Theft Warning System (ATWS) is also
linked with the Central Door Locking Functions
D

T
AF
DOINC054R09068
R
INSPECTION PROCEDURE FOR CENTRAL DOOR LOCKING DIAGNOSIS CODES

WARNING
D

Interior central unlock switch circuit fail- • malfunction of the wiring harness/connect-
B1300
ure ors
• malfunction of the switches or actuators
Interior central lock switch circuit fail- • malfunction of the wiring harness/connect-
B1310
ure/latch door lock switch circuit failure ors
• short circuit to battery
B1301 Latch door unlock circuit failure
ors


(a) For Fault Code B1300 and B1301: Check Fuse No. 23 (15A) OK GO TO 2
(Door Unlock Power) at the Panel Fuse Box
1 Replace and
(b) For Fault Code B1310: Check Fuse No. 18 (15A)(Door Lock NG
Power) at the Panel Fuse Box GO TO 2
mating
Disconnect the BCM Connectors No. C-16 and C-17 and check
(a) Check Voltage between connectors C-17 Pin No. 7 (Door
Lock Power) and
• No. C-17 Pin No. 8 (Ground Power) and
• No. C-16 Pin No. 5 (Ground Signal)
OK: System Voltage
2 Repair/ Re-
NG
T place
AF
DOINC054R09136
(b) Check Voltage/Continuity between connectors C-16 Pin
No. 10 (Door Unlock Power) and
R
• C-17 Pin No. 8 (Ground Power) or

OK: System Voltage
D


and C-17 and check at the Harness Side:
(a) Check Voltage between connector
C-16 Pin No. 10 (Door Unlock Power) and
• Body Earth
OK: System Voltage
3 Repair/ Re-
NG
place
T DOINC054R09142
(b) Check Continuity between BCM Connector C-15 Pin No. 23
(Key Unlock Switch) and
AF
• Body Earth
OK: Continuity exists
(c) Check Continuity between BCM Connector C-15 Pin No. 20
(Unlock Switch) and
• Body Earth
OK: Continuity exists
(d) Check Resistance between BCM Connector C-17 Pin No. 5
R
(All Door Lock) and:

• C-17 Pin No. 6 (Door Unlock)
OK: Resistance Value = 1.5 ± 0.1 Ω (Ignition OFF)
D


For Fault Code B1310: Disconnect the BCM Connectors C-15, OK GO TO 5
C-16 and C-17 and Check at the Harness Side:
Lock Power) and
• Body Earth
OK: System Voltage
4 Repair/ Re-
NG
place
T DOINC054R09142
(b) Check Continuity between connector C-15 Pin No. 37 (Lock
Switch) and
AF
• Body Earth
OK: Continuity
(c) Check Resistance between connector C-17 Pin No. 6 (Door
Unlock) and
• C-17 Pin No. 5 (All Door Lock)
OK: Resistance Value = 1.5 ± 0.1 Ω (Ignition ON/OFF)
R
D


For Fault Code B1301: Disconnect the BCM Connectors C-15, OK GO TO 6
C-16 and C-17 and Check at the Harness Side:
Unlock Power) and
• Body Earth
OK: System Voltage
5 Repair/ Re-
NG
place
T DOINC054R09142
(b) Check Continuity between connector C-15 Pin No. 23 (Key
Unlock Switch) and
AF
• Body Earth
OK: Continuity
(c) Check Continuity between connector C-15 Pin No. 20 (Un-
lock Switch) and
• Body Earth
OK: Continuity
(d) Check Resistance between connector C 17 Pin No. 5 (All
R
Door Lock) and:

• C-17 Pin No. 6
OK: Resistance Value = 1.5 ± 0.1 Ω (Ignition OFF)
D
Check the affected Door Lock/Unlock Switches and Door Latch

Actuators (refer Group Chassis 042 – Door)


Disconnect the BCM Connectors C-15 and Meter Combination OK GO TO 7
(ICU) Connector D- 09 and check the Continuity of the CAN
Bus Wire (Twisted Wire) at the Harness Side:
Check CAN
6 Bus Wire
NG (Twisted Wire)
refer
(a) Check Continuity between connectors C-15 Pin No. 30 (CAN
High BCM) and
OK: Continuity
T
(b) Check Continuity between connectors C-15 Pin No. 40 (CAN
AF
Low BCM) and
OK: Continuity
(refer to Electrical Wiring: Circuit Diagrams-Alarm System
MODULE 4.3, GROUP 14)
OK GO TO 8
R

NG Control Mod-
ule (BCM)
Refer Inspec-
D
tion Chart for

Diagnosis
YES
on page
WCH054TSHOT129
NO STOP

/ 220 CAN BUS SYSTEM
CAN BUS SYSTEM WCH054GINFO12001
CAN COMMUNICATION
CAN NETWORK TOPOLOGY
T
AF
R
DOINC054R09245
D
The CAN Bus System is a communication protocol within the Vehicle Electrical and Electronic System.
The Communication with the all the Electronic Control Units (ECU) and the Diagnostic Tester is done
via the High Speed CAN BUS (HS-CAN 500kbps baud rate)
• Below 8V, BCM will not receive any application CAN messages but transmission of application CAN
messages will remain active.
• Below 7V, BCM will not transmit any application CAN messages.
• Above 15V, BCM will not receive any application CAN messages but transmission of application CAN
messages will remain active.
• Above 18V, BCM will not transmit application CAN messages.
Upon reentering the normal voltage state from an Under or Over Voltage Mode, BCM will reactivate
any previously deactivated outputs if the input conditions for their activation are still true and valid.
Timer functions (such as the Rear Defroster) will be reactivated if their timers have not expired during
the over voltage condition.
LED Indication for Self Diagnostics
There are 2 types of LED Indication for Self Diagnostics.
1. The Self Diagnosis Sequence - Present Blinking (for present/current Fault Codes)

CAN BUS SYSTEM / 221
2. The Self Diagnosis Sequence - Old Blinking (for historical/stored Fault Codes)
The Anti-theft LED indicator in the Instrument Cluster (Combination Meter) will start the Self Diagnosis
Sequence - Present Blinking if all of the below conditions are met if:
• ignition is ON,
• engine is not started and
• present/current DTC (Fault Codes) exists.
The Anti-theft LED indicator in the Instrument Cluster (Combination Meter) will blink Twice (2 times)
every 1 second while in the Self Diagnosis Sequence - Present Blinkingmode. The detailed blinking
sequence is as described below:
• ON for 240 ms
• OFF for 240 ms
• ON for 240 ms
• OFF for 1000 ms
The Anti-theft LED indicator in the Instrument Cluster (Combination Meter) will Start the Self Diagnosis
Sequence - Old Blinking if all of the below conditions are met if:
• ignition is ON,
• engine is not started and
T
• historical/stored DTC (Fault Codes) exists.
The Anti-theft LED indicator in the Instrument Cluster (Combination Meter) will be ON continuously
while in the Self Diagnosis Sequence - Old Blinkingmode.
AF
If the DTC (Fault Codes) have been erased, the blinking will stop.
CAN SIGNAL MEASUREMENT

1. Connect the Vehicle Measurement Interface
R
(VMI) to the Diagnostic connector D-11 as

shown in the figure.
2. Connect the Red DMM Cable (EZT 0031) to
Channel 1 of the Vehicle Measurement Inter-
D
face (VMI). This channel will be used to dis-

play the CAN High waveform.
3. Connect the Positive Probe of the Red DMM
Cable to Pin No. 6 (CAN High) on the Dia-
DOINC054R09221 gnostic Connecter (D-11).
4. Connect the Negative Probe of the Red DMM
Cable to Pin No. 5 (Ground) on the Diagnostic
Connecter (D-11).
5. Connect the Yellow DMM Cable (EZT 0031)
to Channel 2 of the Vehicle Measurement
Interface (VMI). This channel will be used to
display the CAN Low waveform.
6. Connect the Positive Probe of the Yellow
DMM Cable to Pin No. 14 (CAN Low) on the
Diagnostic Connecter (D-11).
7. Connect the Negative Probe of the Yellow
DMM Cable to Pin No. 4 (Ground) on the
Diagnostic Connecter (D-11).
8. Connect the Vehicle Measurement Interface
(VMI) to the PADT-07 Diagnostic Tool and

/ 222 CAN BUS SYSTEM
turn ON the Ignition. Go to the Oscilloscope

section.
T
AF
R
DOINC054R09239
9. Once the waveform is displayed on the screen

as shown in the figure, adjust the display
D
settings as described in the table below.
Setting Value
Voltage Scale 1V
Time/ Div 10 µs
Trigger Level
5V
(for Channel 2)

CAN BUS SYSTEM / 223
T
AF
DOINC054R09241
R
10. Press the 'Down' button under CH1 to move

the position of the CAN High waveform so
that it overlaps with the CAN Low waveform
as shown in the figure.
D
11. Press the hold button to freeze the screen.

12. Position cursor A at the minimum differential
point of the waveform (where the CAN High
and CAN Low waveforms overlap) to check
the Recessive Voltage.
13. Position cursor B at the maximum differential
point of the waveform (where the CAN High
and CAN Low waveforms overlap) to check
the Dominant Voltage.

/ 224 ADVANCED BODY CONTROL MODULE (ABCM)
14. Check that the waveform displayed on the

PADT-07 screen matches the waveform
shown in the figure. Calculate and compare
the value of both the Recessive Voltage and
the Dominant Voltage, it should be within
the standard value.
DOINC054R09200
CAN BUS SPECIFICATION

CAN BUS VOLTAGE SPECIFICATION
VOLTAGE CALCULATION METHOD STANDARD VALUE
DIFFERENTIAL RECESSIVE VOLTAGE
Volt A CH1 – Volt A CH2 - 0.12- - - - V to 0.12 V
CAN High – CAN Low
DIFFERENTIAL
VOLTAGE
DOMINANT
T
Volt B CH1 – Volt B CH2 1.2 V to 3.0 V
AF
CAN High – CAN Low
ADVANCED BODY CONTROL MODULE (ABCM) WCH054GINFO12002
GENERAL INFORMATION
R
The Advanced Body Control Module (ABCM) is an integrated control module which controls the basic
or standard vehicle electrical functions by eliminating individual control units and reducing the
number of external relays.
The PROTON ABCM controls most of the body functions of the vehicle; the communication with the
D
units and the diagnostic tester is done via the High Speed CAN BUS (HS-CAN 500kbps baud rate)
The Basic or Standard Vehicle Electrical Functions controlled by the ABCM are as listed below:
No Function Features
Front wiper low speed & high speed mode
Front wiper intermittent mode with Rheostat
Front wiper speed mode (wiper mode shift when vehicle
stops)
1. +Wiper/Washer Front wash wiping
Front wash prolongation & drip wiping
Auto wiping function with RLS (via LIN)
Rear wiper *
Rear washer and wash wiping *
Courtesy lighting with theatre dimming
Background illumination (level adjustable via CAN)
2. +Interior Lighting & BSR Battery saving with BSR cutoff timer
Anti theft LED
Door lock status LED

ADVANCED BODY CONTROL MODULE (ABCM) / 225
No Function Features
Turn signal flashing
Lane change flashing(Number from CAN)
Hazard flashing with hazard switch
3. +Flasher Hazard flashing on emergency brake
Hazard flashing on crash condition
Alarm warning for ATWS
Acknowledge of central lock/unlock confirmation
Position lamp
Low beam
High beam
Day Time Running Light
Stop lamp
CHMSL
4. +Exterior Lighting
Home safe light / follow home light via headlamp
Approach Light
Vehicle search light
Front fog lamps (with auto cancellation)
Rear fog lamps (with auto cancellation)
T
Auto light on (use rain/light sensor via LIN)
5. +Heating Function Rear window defroster
Door ajar warning (via CAN)
AF
Lights left on warning (via CAN)
+Driver Information
6. RKE low batter indication (via CAN)
Warning
Seat belt warning (LED+signal to IP via CAN)
Buzzer Acknowledgement for RKE commands
Key cylinder central lock
Remote central lock/unlock
R
Remote trunk release

Reserve unlock
Door ajar reminding
+Central Locking/Unlock- Auto relocking
7.
D
ing Speed lock

Crash unlock (via CAN)
2 stage central unlock (with remote toggle)
Door latch overheating protection
Ignition off unlock
Super Lock *
Panic Alarm (via vehicle horn)
8. +ATWS
Perimeter Alarm (via vehicle horn)
+Diagnostics/Service
9. Compliant with ISO-14229 (UDS) on CAN
Mode
10. +SSB Power moding control
Mirror fold/unfold
Vehicle Horn (direct control by the input)
HS CAN with NWM
11. +Others 2 LIN bus (2.0)
Power Management for Quiscient Current
Voltage Mode Management
Power window enable

ABCM CONNECTORS
T
AF
R
DOIQC054R12008
SYMBOL CONNECTOR
D
DOIQC054R12002
Connector C15

SYMBOL CONNECTOR
DOIQC054R12003
Connector C16
T
AF
3
DOIQC054R12004
R
Connector C17
D
DOIQC054R12005

SYMBOL CONNECTOR
DOIQC054R12006
T
AF
DOIQC054R12007
R
D

ABCM OUTER SCHEMATICS
T
AF
R
D
DOIQC054R12009

POWER MANAGEMENT
The BCM shall operate normally at voltage level between rang 9V to 16V, except immobilizer function,
which should work between range 6V to 16V.
The BCM provides a voltage mode management to ensure that no hardware device will be damaged
by the operation of software applications. In order to avoid any malfunction of hardware devices,
BCM monitors the voltage supply and performs special actions immediately once the operating voltage
enters or leaves a specific voltage mode.
To maintain the optimum operation of ABCM, replace battery when the battery voltage is exceed/below
normal battery voltage operation.
SELF DIAGNOSIS
DTC Trouble Code Description Possible Fault Causes
Number
U012987 Lost Communication With GSL Lost Communication With Gear Shift Lock disconnection
Gear Shift Lock
U010087 Lost Communication With Lost Communication With En- EMS disconnection
EMS gine Management System
U010187 Lost Communication With

T
U015187 Lost Communication With SRS Lost Communication With
Airbag Control Unit
Lost Communication With
Airbag Control Unit disconnec-
tion
TCU disconnection
AF
TCU TCU
U015587 Lost Communication With ICU Lost Communication With In- Instrument Cluster Unit discon-
strument Cluster Unit nection
U007388 CAN Bus off CAN Bus-Off fault CAN Bus off
B116000 GSL Lock position sensor GSL (Gear Shift Lock) Lock Lock sensor loop Failed
R
status error (01) position sensor status

B116100 GSL UnLock position sensor GSL(Gear Shift Lock) Unlock Unlock sensor loop Failed
B116300 GSL UnLock position sensor GSL (Gear Shift Lock) Unlock Sensor loops all Failed
D
status (03) position sensor status

U019987 Lost Communication With RLS Lost Communication With Rain Light Sensor disconnec-
Module Rain Light Sensor Module tion
U016987 Lost Communication With Lost Communication With Re- Reverse Parking Aid disconnec-
RPA module verse Parking Aid module tion
U201088 LIN-1 communication error ABCM is not able to transmit LIN bus circuit shortcut
a master request frame on the
LIN-1
LIN-2
B130000 Rain sensor calibration error Error calibration rain sensor Error calibration rain sensor
B131000 Rain sensor coding error Error status of coding rain The light/solar/HUD function
sensor requires a coding of the RLS.
Without coding of the wind-
screen variant (transmission
rate), no valid sensor values
will be output.


Number
B13201C Rain sensor voltage out of Error status of rain sensor Circuit voltage out of range.
range The rain sensor continuously
checks the values of its meas-
uring sections. If the values
are no longer inside the valid
range, then the rain sensor
will attempt an adjustment
of the values. The error will
be set if automatic adjust-
ment is not possible.
B133000 Light sensor function error Error status of light sensor Is set in the case of a hard-
ware error of the light sensor
system.
B13404B RLS Over temperature Error status of over temperat- Over temperature. The RLSBS
ure detects its ambient temperat-
ure. If a temperature of 85°C
B135017 RLS overvoltage Error status of over voltage Circuit voltage above
T threshold. The RLSBS detects

its voltage supply. If 17.5 V
are exceeded
AF
B136000 RLS signal error Rain Light Sensor error Collective error signal of the
Rain Light Sensor sensor
B137000 RLS Communication error Communication error LIN communication error
B110017 Battery Voltage High Battery Voltage abnormal circuit voltage above
high threshold. Battery Voltage
abnormal high
R
B110016 Battery Voltage Low Battery Voltage abnormal low Battery Voltage abnormal low
B110118 Lost voltage (Vbatt - CDL) AI_VBAT_CDL is lost circuit voltage above
threshold. Battery Voltage
D
abnormal low
B110218 Lost voltage (Vbatt - KL30) AI_VBAT_KL30 is lost Battery Voltage abnormal low
B116200 ABCM Internal failure ECU Internal failure (can not ECU Internal failure
perform this test)
B11512A Flasher handler stuck failure Flasher handler stuck failue handler stuck
B11B311 Brake light stuck or short cir- Brake light circuit failure Brake light circuit failure
cuit to GND short circuit to battery stuck
B11B312 Brake light short circuit to or short circuit to GND open
battery circuit
B11B313 Brake light open circuit
B11B412 3rd brake light short circuit C High Mounted Stop Lamp C High Mounted Stop Lamp
to battery (CHSML) light circuit failure light circuit failure short cir-
B11B411 3rd brake light stuck or short cuit to battery stuck or short
circuit to GND (CHSML) circuit to GND open circuit
B11B413 3rd brake light open circuit
(CHSML)


Number
B11D214 Right turn light bulb is out- Right turn light failure Right turn light failure
age
B11D215 Right turn light short to bat-
tery or open circuit
B11D219 Right turn light Over Current
B11D314 Left turn light bulb is outage Left turn light failure Left turn light failure
B11D315 Left turn light short to bat-
B11D319 Left turn light Over Current
B11D419 SSB Ignition ON failure - Over IGN ON failure IGN ON failure
Current
B11D413 SSB Ignition ON failure - open
circuit
B11D519 SSB Ignition OFF failure - Over IGN OFF failure IGN OFF failure
Current
B11D512 SSB Ignition OFF failure -
T
AF
open circuit
B11D619 SSB Crank failure - Over Cur- Crank failure Crank failure
rent
B11D612 SSB Crank failure - short cir-
cuit to battery
B11D613 SSB Crank failure - open cir-
R
cuit
B113D2A Front wiper park switch stall Front wiper park switch fail- Front wiper park switch stall
ure
D
B115011 Front wiper rheostat open Front wiper rheostat Open rheostat open circuit
circuit Circuit failure
B115012 Front wiper rheostat short Front wiper rheostat Short rheostat short to battery
circuit to battery Circuit failure
B211223 Front washer switch stuck Front washer switch failure Front washer switch failure
B169323 SSB switch stuck Start Stop Button switch Stuck Start Stop Button switch fail-
failure ure
B169223 SSB switch Mismatch Start Stop Button switch Mis- Start Stop Button switch fail-
match failure ure
B169313 SSB Self-Latching open circuit Self-Latching circuit open self-latching circuit failure
B169467 SSB Signal incorrect (cannot can not turn off ignition Signal incorrect after event.
turn Ignition OFF) can not turn off ignition
B169586 SSB Signal invalid (cannot can not turn on ignition Signal invalid. can not turn on
turn Ignition ON) ignition
B169123 Mirror fold /Unfold switch mirror fold/unfold switch mirror fold/unfold switch
Stuck Stuck failure failure

INSPECTION CHART FOR TROUBLE CODE WCH054TSHOT12003
DTC Number Trouble Code Reference page

U012987 Lost Communication With GSL
U010087 Lost Communication With EMS
U015187 Lost Communication With SRS
U010187 Lost Communication With TCU
U015587 Lost Communication With ICU
U007388 CAN Bus off
B116000 GSL Lock position sensor status error (01)
B116100 GSL UnLock position sensor status error (02)
B116300 GSL UnLock position sensor status (03)
U019987 Lost Communication With RLS Module
U016987 Lost Communication With RPA module
U201088 LIN-1 communication error
B130000 Rain sensor calibration error
B131000
B13201C
B133000
Rain sensor coding error
Rain sensor voltage out of range
Light sensor function error
T
AF
B13404B RLS Over temperature
B135017 RLS overvoltage
B136000 RLS signal error
B137000 RLS Communication error
B110017 Battery Voltage High
R
B110016 Battery Voltage Low

B110118 Lost voltage (Vbatt - CDL)
B110218 Lost voltage (Vbatt - KL30)
D
B116200 ABCM Internal failure

B11512A Flasher handler stuck failure
B11B312 Brake light short circuit to battery
B11B311 Brake light stuck or short circuit to GND
B11B412 3rd brake light short circuit to battery (CHSML)
B11B411 3rd brake light stuck or short circuit to GND (CHSML)
B11B413 3rd brake light open circuit (CHSML)
B11D214 Right turn light bulb is outage
B11D215 Right turn light short to battery or open circuit
B11D314 Left turn light bulb is outage
B11D315 Left turn light short to battery or open circuit
B11D419 SSB Ignition ON failure - Over Current
B11D413 SSB Ignition ON failure - open circuit

DTC Number Trouble Code Reference page

B11D519 SSB Ignition OFF failure - Over Current
B11D512 SSB Ignition OFF failure - short circuit to battery
B11D513 SSB Ignition OFF failure - open circuit
B11D619 SSB Crank failure - Over Current
B11D612 SSB Crank failure - short circuit to battery
B11D613 SSB Crank failure - open circuit
B113D2A Front wiper park switch stall
B115011 Front wiper rheostat open circuit
B115012 Front wiper rheostat short circuit to battery
B211223 Front washer switch stuck
B169323 SSB switch stuck
B169223 SSB switch Mismatch
B169313 SSB Self-Latching open circuit
B169467 SSB Signal incorrect (cannot turn Ignition OFF)
B169586 SSB Signal invalid (cannot turn Ignition ON)
B169123
DATA LIST
Mirror fold /Unfold switch Stuck
T WCH054TSHOT12004
AF
No PADT-II Display Standard value
Switch OFF / while in- Switch ON / while
active active
1 Left Turn Signal (Switch) OFF ON
2 Right Turn Signal (Switch) OFF ON
R
3 Hazard Signal (Momentary Switch) OFF ON

4 Front Fog Lamp (Momentary Switch) (If OFF ON
fitted)
D
5 Rear Fog Lamp (Momentary Switch) (If OFF ON

fitted)
6 Park Lamp (Switch) OFF ON
7 High Beam Signal (Switch) 00 - OFF 01 - ON
8 Low Beam Signal (Switch) OFF ON
9 Brake Switch Input Status OFF ON
10 Headlamp Off Status (Switch) OFF ON
11 Hood Ajar NO YES
12 Tailgate / Trunk Ajar NO YES
13 Rear Right Door Ajar NO YES
14 Rear Left Door Ajar NO YES
15 Front Right Door Ajar NO YES
16 Front Left Door Ajar NO YES
17 Mirror Fold/Unfold (Momentary Switch) OFF ON
(If fitted)
18 Rear Defogger/Defrost (Momentary OFF ON
Switch)

No PADT-II Display Standard value

Switch OFF / while in- Switch ON / while
active active
19 Driver Door Lock status (Switch) UNLOCK LOCK
20 Horn (Momentary Switch) OFF ON
21 Interior Central Lock/Unlock (Momentary Not Pressed Pressed
Switch)
22 Front Wiper Park status OFF ON
23 Front Wiper High speed (Switch) OFF ON
24 Front Wiper Low speed (Switch) OFF ON
25 Front Washer (Momentary Switch) OFF ON
26 SSB1 (momentary switch) OFF ON
27 SSB2 (momentary switch) OFF ON
28 Ignition status OFF ON
29 Key in status OFF ON
30 Reverse Gear OFF ON
31 Number of Programmed Keys Min key programmed: 0
ACTUATOR TEST
TMax keys programmed: 5
AF
WCH054TSHOT12005
No PADT-II Display Test method Remarks

1 Turn Lamp Signal PADT-II will automatically con- This test will sequentially turn ON
Control duct test as sequence; right turn lamp for 3 sec and Left
a. Turn ON right turn lamp for turn lamp for another 3 sec.
3 sec
R
b. Turn ON left turn lamp for 3

sec
c. Turn OFF All lamps
2 Exterior Lamp Control PADT-II will automatically con- This test will sequentially turn ON
D
duct test as sequence; 3 sec each of the equipped exter-

a. Turn ON 3rd brake lamp for ior lamps starting from 3rd brake
3 sec lamp, front fog lamp, rear fog
b. Turn ON front fog lamp for 3 lamp, brake lamp, low beam
sec lamp, park lamp, daytime running
c. Turn ON rear fog lamp for 3 lamp and high beam lamp.
sec
d. Turn ON brake lamp for 3 sec
e. Turn On low beam lamp for
3 sec
f. Turn ON park lamp for 3 sec
g. Turn ON daytime running
lamp for 3 sec
h. Turn ON high beam for 3 sec
i. Turn OFF All lamps

No PADT-II Display Test method Remarks

3 Interior Lamp Control PADT-II will automatically con- This test will sequentially turn ON
duct test as sequence; 3 sec of battery saver and interior
a. Turn On battery saver lamp, and consecutive 3 sec each
b. Turn ON interior lamp for 3 for background illumination,
sec Start-Ready-LED and Start-Not-
c. Turn ON background illumin- Ready-LED.
ation for 3 sec
d. Turn ON start ready LED for
3 sec
e. Turn ON start not ready LED
f. Turn OFF All lamps
4 Front Wiper & Wash- PADT-II will automatically con- This test will sequentially turn ON
er Control duct test as sequence; consecutively 3 sec each of the
a. Turn ON front washer for 3 front washer, low speed front
sec wiper and high speed front wiper.
b. Turn ON front wiper low
speed for 3 sec
c. Turn ON front wiper high
T
speed for 3 sec
d. Turn OFF All actuators.
5 Alarm Status Control PADT-II will automatically con- This test will sequentially turn ON
AF
duct test as sequence; consecutively 3 sec each of the
a. Turn ON Passenger seatbelt Passenger Seat belt Reminder
reminder for 3 sec LED, Antitheft or Control Door
b. Turn ON anti-theft LED for 3 Lock LED, Alarm horn and buzzer.
sec
c. Turn ON alarm horn for 3 sec
d. Turn ON buzzer for 3 sec
R
e. Turn OFF All actuators.

6 Driver Door Unlock Turn Unlock button - user con- Check on Driver's Door Unlock
Control trol activation
D
7 Central Lock / unlock Turn Unlock and Lock button - Check on Central Door Lock and
Control user control Unlock activation
8 Power Window Con- Turn Disable and Enable button Check on Power Window activa-
trol - user control tion
9 Mirror Fold/Unfold Mirror Unfold and Fold selection Check on Mirror Fold and Unfold
Control (same as EXORA BFC) activation
10 Trunk release control Turn Release button - user con- Check on Trunk Relase activation
trol
11 Rear defogger/de- Turn ON and OFF button - user Check on the Rear Defogger activ-
frost relay control control ation
12 ACC state control Start and Stop button - user Check the ACC status
control
13 Crank control Start and Stop button - user Check on the crancking activation
control
14 Ignition control ON and OFF button - user con- Check on IG ON and OFF status
trol; return control to ECU when
user exit the page.

INSPECTION CHART FOR TROUBLE SYMPTOMS WCH054TSHOT12006

No Communication with the Communication with all systems is not possible.
WCH054TSHOT188
PADT-II Communication with ABCM is not possible.
All ABCM Related functions are not working WCH054TSHOT189
TROUBLE SYMPTOM: NO COMMUNICATION WITH PADT-II WCH054TSHOT12007
NO COMMUNICATION WITH PADT-II Probable cause

wire.
T
AF
R
D
DOINC13AR09024
TROUBLE SYMPTOM: ALL BCM RELATED FUNCTION ARE NOT WORKING WCH054TSHOT12008
ALL BCM RELATED FUNCTION ARE NOT WORKING Probable cause

• Battery voltage above/below
The cause is probably a defect in the power supply system (including normal operation voltage
earth) . • ABCM malfunction

T
AF
DOINC13AR09024
R
CODE: U012987, U010087, U015187, U010187, U015587, U019987 & U016987. WCH054TSHOT12009
TROUBLE PADT DISPLAY DESCRIPTION POSSIBLE FAULT CODES

CODE
D
U012987 Lost Communication With GSL Lost Communication With Gear Shift Lock disconnection
Gear Shift Lock
U010087 Lost Communication With Lost Communication With En- EMS disconnection
EMS gine Management System
U015187 Lost Communication With SRS Lost Communication With Airbag Control Unit disconnec-
Airbag Control Unit tion
U010187 Lost Communication With Lost Communication With TCU disconnection
TCU TCU
U015587 Lost Communication With ICU Lost Communication With In- Instrument Cluster Unit discon-
strument Cluster Unit nection
U019987 Lost Communication With RLS Lost Communication With Rain Light Sensor disconnec-
Module Rain Light Sensor Module tion
U016987 Lost Communication With Lost Communication With Re- Reverse Parking Aid disconnec-
RPA module verse Parking Aid module tion

CODE: U007388 WCH054TSHOT12010

CODE
U007388 CAN Bus off CAN Bus-Off fault CAN Bus off
CODE: U007388 WCH054TSHOT12011

CODE
B116000 GSL Lock position sensor GSL (Gear Shift Lock) Lock Lock sensor loop Failed
B116100 GSL UnLock position sensor GSL (Gear Shift Lock) Unlock Unlock sensor loop Failed
B116300 GSL UnLock position sensor GSL (Gear Shift Lock) Unlock Sensor loops all Failed
status (03) position sensor status
CODE: U201088 & U201188 WCH054TSHOT12012

CODE
T
ABCM is not able to transmit LIN bus circuit shortcut
AF
LIN-1
LIN-2
CODE: U201088 & U201188 WCH054TSHOT12013

R
TROUBLE PADT DISPLAY DESCRIPTION POSSIBLE FAULT CAUSES

CODE
D

LIN-1
LIN-2
CODE: B131000, B13201C, B133000, B13404B, B135017, B136000 & B137000 WCH054TSHOT12014

CODE
B131000 Rain sensor coding error Error status of coding rain The light/solar/HUD function
sensor requires a coding of the RLS.
Without coding of the wind-
screen variant (transmission
rate), no valid sensor values
will be output.


CODE
B13201C Rain sensor voltage out of Error status of rain sensor Circuit voltage out of range.
range The rain sensor continuously
checks the values of its meas-
uring sections. If the values
are no longer inside the valid
range, then the rain sensor
will attempt an adjustment
of the values. The error will
be set if automatic adjust-
ment is not possible.
B133000 Light sensor function error Error status of light sensor Is set in the case of a hard-
ware error of the light sensor
system.
B13404B RLS Over temperature Error status of over temperat- Over temperature. The RLSBS
ure detects its ambient temperat-
ure. If a temperature of 85°C
B135017 RLS overvoltage Error status of over voltage Circuit voltage above
T threshold. The RLSBS detects

its voltage supply. If 17.5 V
are exceeded
AF
B136000 RLS signal error Rain Light Sensor error Collective error signal of the
Rain Light Sensor sensor
B137000 RLS Communication error Communication error LIN communication error
CODE: B110118 & B110218 WCH054TSHOT12015

R

CODE
B110118 Lost voltage (Vbatt - CDL) AI_VBAT_CDL is lost Circuit voltage above
threshold. Battery Voltage
D
abnormal low
B110218 Lost voltage (Vbatt - KL30) AI_VBAT_KL30 is lost Battery Voltage abnormal low
CODE: B11512A WCH054TSHOT12016

CODE
B11512A Flasher handler stuck failure Flasher handler stuck failue Handler stuck
CODE: B11B311 , B11B312 & B11B313 WCH054TSHOT12017

CODE
B11B311 Brake light stuck or short cir- Brake light circuit failure Brake light circuit failure
cuit to GND short circuit to battery stuck
B11B312 Brake light short circuit to or short circuit to GND open
battery circuit

CODE: B11B411 , B11B412 & B11B413 WCH054TSHOT12018

CODE
B11B411 3rd brake light stuck or short C High Mounted Stop Lamp C High Mounted Stop Lamp
circuit to GND (CHSML) light circuit failure light circuit failure short cir-
B11B412 3rd brake light short circuit cuit to battery stuck or short
to battery (CHSML) circuit to GND open circuit
B11B413 3rd brake light open circuit
(CHSML)
CODE: B11D214 , B11D215 & B11D219 WCH054TSHOT12019

CODE
B11D214 Right turn light bulb is out- Right turn light failure Right turn light failure
age
B11D215 Right turn light short to bat-
T

AF
CODE
B11D314 Left turn light bulb is outage Left turn light failure Left turn light failure
B11D315 Left turn light short to bat-
R
CODE: B11D413 , B11D419, B11D512, B11D513, & B11D519 WCH054TSHOT12021

D
CODE
B11D413 SSB Ignition ON failure - open IGN ON failure IGN ON failure
circuit
B11D419 SSB Ignition ON failure - Over
Current
B11D512 SSB Ignition OFF failure - IGN OFF failure IGN OFF failure
open circuit
B11D519 SSB Ignition OFF failure - Over
Current


CODE
B11D612 SSB Crank failure - short cir- Crank failure Crank failure
cuit to battery
B11D613 SSB Crank failure - open cir-
cuit
B11D619 SSB Crank failure - Over Cur-
rent
CODE: B113D2A , B115011 & B115012 WCH054TSHOT12023

CODE
B113D2A Front wiper park switch stall Front wiper park switch fail- Front wiper park switch stall
ure
B115011 Front wiper rheostat open Front wiper rheostat Open rheostat open circuit
circuit Circuit failure
T
B115012 Front wiper rheostat short Front wiper rheostat Short rheostat short to battery
circuit to battery Circuit failure
AF
CODE: B211223 WCH054TSHOT12024

CODE
B211223 Front washer switch stuck Front washer switch failure Front washer switch failure
CODE: B169323, B169223, B169313 , B169467 & B169586 WCH054TSHOT12025

R

CODE
B169323 SSB switch stuck Start Stop Button switch Stuck Start Stop Button switch fail-
D
failure ure
B169223 SSB switch Mismatch Start Stop Button switch Mis- Start Stop Button switch fail-
match failure ure
B169313 SSB Self-Latching open circuit Self-Latching circuit open self-latching circuit failure
B169467 SSB Signal incorrect (cannot can not turn off ignition Signal incorrect after event.
turn Ignition OFF) can not turn off ignition
B169586 SSB Signal invalid (cannot can not turn on ignition Signal invalid. can not turn on
turn Ignition ON) ignition
CODE: B169123 WCH054TSHOT12026

CODE
B169123 Mirror fold /Unfold switch mirror fold/unfold switch mirror fold/unfold switch
Stuck Stuck failure failure

HEATER, AIR CONDITIONER AND VENTILATION 55
Content /1
55 HEATER, AIR CONDITIONER AND VENTILATION

SAFETY PRECAUTIONS ............................................................. 55/4
SPECIFICATIONS ....................................................................... 55/4

LUBRICANTS ......................................................................... 55/5
SEALANT .............................................................................. 55/5
SPECIAL TOOLS ........................................................................ 55/6

TOOLS ................................................................................. 55/6
SERVICE AND REPAIR ................................................................. 55/7

SERVICE TOOLS AND GAS LEAK DETECTOR (FOR HFC 134a) ............... 55/7
SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/7
HANDLING OF SERVICE TOOLS ................................................... 55/9
PRECAUTION FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/13
EVACUATING AND CHARGING .....................................................

T
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/16
55/17
AF
TROUBLESHOOTING PROCEDURE ............................................... 55/17
CAUTION IN HANDLING THE REFRIGERANT ................................... 55/17
AIR-COND SERVICE TOOL ......................................................... 55/18

RECEIVER DRIER TEST .............................................................. 55/21
DUAL PRESSURE SWITCH CHECK ................................................ 55/22
R
PERFORMANCE TEST ............................................................... 55/23

REFILLING OF OIL IN THE A/C SYSTEM .......................................... 55/24
REFRIGERANT LEAK REPAIR ...................................................... 55/24
D
LOST CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/24

LOW CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/24
HANDLING TUBING AND FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/24
COMPRESSOR NOISE ............................................................... 55/25
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/25
POWER RELAY CHECK ............................................................. 55/26
BLOWER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/26
PCB RELAY A/C COMPRESSOR BUILT-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/26
AIR-COND CONTROL ASSEMBLY ................................................... 55/27

CONTROL ASSY VENTILATOR ....................................................... 55/29

INSPECTION SERVICE POINT ...................................................... 55/29
SPECIFICATION FOR CONTROL ASSY VENTILATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/29
COOLER ASSY UNIT AND BLOWER ASSY UNIT ................................. 55/31

COOLER ASSY UNIT .................................................................. 55/32

COOLER UNIT ASSY AND BLOWER UNIT ASSY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/32

/2 Content

BLOWER FILTER COVER REMOVAL .............................................. 55/32
MAIN FUNCTIONAL COMPONENTS ............................................... 55/33

THERMO AMP SENSOR ............................................................ 55/33
THERMO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/34
RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/34
COOLER ASSY UNIT .................................................................. 55/35

REFRIGERANT LINE ................................................................... 55/36

REFRIGERANT LINE FRONT .......................................................... 55/38

AIR COND COMPRESSOR (CFE) ..................................................... 55/39

COMPRESSOR ..........................................................................
T 55/41
55/41
AF
INSPECTION .......................................................................... 55/42
COMPRESSOR MAGNETIC CLUTCH OPERATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 55/42
CONDENSER AND CONDENSER FAN MOTOR ................................... 55/43

R
INSPECTION .......................................................................... 55/46

CONDENSER FAN AND MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/46
VENTILATORS .......................................................................... 55/47

D
FRONT DUCT ......................................................................... 55/47

REAR DUCT ........................................................................... 55/48

Content /3
NOTE
T
AF
R
D

The Air-Cond system uses a one -way-flow system that features high performance and low operating
noise, and includes an independent face air blowing function.
The A/C system is basically the same as the conventional system, but a new refrigerant system has
been adopted as a response to restrictions on the use of chlorofluorocarbons.
SAFETY PRECAUTIONS
Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of
chlorine atoms, it will not cause damage to the ozone layer.
Refrigerant R-134a is transparent and colourless in both the liquid and vapour state. Since it has a
boiling point of –29.8 °C (85.64 °F), at atmospheric pressure, it will be a vapour is heavier than air,
non-flammable, and nonexplosive. The following precautions must be observed when handling R-
134a.
CAUTION
Wear safety goggles when servicing the refrigeration system.
R-134a evaporates so rapidly at normal atmospheric pressures and temperatures that it tends to
freeze anything it contacts. For this reason, extreme care must be taken to prevent any liquid refri-
gerant from contacting the skin and especially the eyes. Always wear safety goggles when servicing
the refrigeration part of the A/C system. Keep a bottle of sterile mineral oil handy when working on
T
the refrigeration system. Should any liquid refrigerant get into the eyes, use a few drops of mineral
oil to wash them out. R-134a is rapidly absorbed by the oil. Next splash the eyes with plenty of cold
water. Call your doctor immediately even though irritation has ceased after treatment.
AF
CAUTION
Do not heat R-134a above 40 °C (104 °F)
In most instances, moderate heat is required to bring the pressure of the refrigerant in its container
above the pressure of the system when charging or adding refrigerant.
A bucket or large pan of hot water not over 40 °C (104 °F) is all the heat required for this purpose.
Do not heat the refrigerant container with a blow torch or any other means that would raise temper-
R
ature and pressure above this temperature. Do not weld or steam clean on or near the system com-
ponents or refrigerant lines.
CAUTION
D
Keep R-134a containers upright when charging the system.

When metering R-134a into the refrigeration system keep the supply tank or cans in an upright pos-
ition. If the refrigerant container is on its side or upside down, liquid refrigerant will enter the system
and damage the compressor.
CAUTION
(1) The leak detector for R-134a should be used to check for refrigerant gas leaks.
(2) Do not allow liquid refrigerant to touch bright metal.
Refrigerant will tarnish bright metal and chrome surfaces, and in combination with moisture can
severely corrode all metal surfaces.
Air distributor assembly Type Single flow system
Air-cond control assembly Dial type
Compressor model APM A/C DKS – 17DS

SPECIFICATIONS /5
PATCO
ON → OFF : 3138 kPa (446.41 psi, 947.3
High pressure in.Hg)
switch
OFF → ON : 2550 kPa (362.76 psi, 769.79
Dual Pressure Switch
in.Hg)
ON → OFF : 196 kPa (27.88 psi, 59.17 in.Hg)

Low pressure
switch OFF → ON : 221 kPa (31.44 psi, 66.72 in.Hg)
R-134a, Approx.
Refrigerant and quantity 550 g (19.4 oz, 5.5 N) ± 50 g (1.76 oz, 0.5
N)
Idle speed 750 r/min ± 100 r/min
Idle up speed 900 r/min ± 50 r/min
Between termin-
T
Between termin-
als 1 and 2
Front
Rear
Front
1.34 Ω ± 10 %
2.22 Ω ± 10 %
1.9 Ω ± 10 %
AF
Blower Resistor
als 1 and 3 Rear 3.34 Ω ± 10 %
Between termin- Front 2.23 Ω ± 10 %
als 1 and 4 Rear 4.05 Ω ± 10 %
OFF(no con- 107 °C (224.6 °F)
tinuity)
A/T
R
ON(continu- 103 °C (217.4 °F)

Engine coolant temperature switch (For ity)
A/C cut-off) OFF(no con- 115 °C (239 °F)
D
tinuity)
M/T
ON(continu- 110 °C (230 °F)
ity)
LUBRICANTS
200 - 220 cm³ (12.2 - 13.42
Compressor refrigerant unit lubricant APMCC ZXL 100PG
cu.in)
SEALANT
Items Specified sealant Remark
Engine coolant temperature switch 3M Adhesive Nut Locking No.
Drying sealant
threaded portion 4171 or equivalent

/6 SPECIAL TOOLS
TOOLS
Tools Number Name Use
MB990784 Ornament remover Removal of Aircond assembly
DOIHC051R04017
TROUBLESHOOTING CHECKING
Use the table below to help you find the cause of the problem. Check each part in order. If necessary,
replace these parts.
Trouble symptom Main inspection areas

A/C fuse
No blower operation
T
Main blower relay
Blower motor
Blower speed control switch
AF
Blower resistor
Refrigerant volume
A/C fuse
Compressor relay
Magnetic clutch relay
R
Magnetic clutch
Compressor
No compressor operation
Pressure switch
D
Thermister
A/C switch
A/C ECU
Wire harness
Water temperature sensor
Refrigerant volume
Compressor relay
Magnetic clutch relay
Compressor operates intermittently Pressure switch / sensor
Magnetic clutch
Fead belt
Compressor
Condenser fan relay
No condenser fan operation Pressure switch
Condenser fan motor

SERVICE AND REPAIR /7
Trouble symptom Main inspection areas

Refrigerant volume
Fead belt
Magnetic clutch
Compressor
No cool air comes out
Pressure switch / sensor
Thermister
A/C ECU
A/C switch
Refrigerant volume
Fead belt
A/C ECU
Cool air comes out intermittently
Expansion valve
Evaporator
Thermister
Refrigerant volume
Fead belt
Compressor
Condenser
T
AF
Cool air comes out only at high engine rpm
Receiver
Expansion valve
Evaporator
Refrigerant lines
Refrigerant volume
R
Fead belt
Condenser fan relay
Condenser fan motor
D
Insufficient cooling Condenser

Receiver
Expansion valve
Evaporator
Refrigerant lines
A/C switch
No engine idle up when A/C switch on A/C ECU
Wire harness
SERVICE AND REPAIR WCH055SPROC11002
SERVICE TOOLS AND GAS LEAK DETECTOR (FOR HFC 134a)

SERVICE TOOLS
Special service tools are used for servicing the air conditioner as shown below.
For HFC 134a system, to prevent incorrect refrigerant changing and to prevent compressor oil from
getting mixed, the diameter for each joint has been changed to use quick disconnect adapter compat-
ible with SAE standard changing valves.

/8 SERVICE AND REPAIR
Order No. of car Air Conditioner Service Tool Set : 07110–58011.
T
AF
R
DOIIC055R01103
Symbol Description
A Manifold gauge
D
B Charging hose
C Vacuum pump adapter
D Quick disconnect adapter

SERVICE AND REPAIR /9
HANDLING OF SERVICE TOOLS

WCH055SPROC11003
1. Connecting Manifold Gauge

CAUTION
• Always use manifold gauge for the HFC
134a air conditioning system
Symbol Description
A Manifold gauge
B Low pressure charging hose
C Quick disconnect adapter
(Suction)
D High pressure charging hose
E Center charging hose
F Quick disconnect adapter
(Discharge)
G Center hose
T
AF
DOIIC055R01104
2. Connecting the Quick Disconnect Adapter

Push the quick disconnect adapter into the
charging valve. Then push on part “A” as
R
shown in the illustration until a click is heard

⇒ Connection completed
CAUTION
D
(1) When connecting, push carefully so the

piping doesn't bend.
(2) When connecting the quick disconnect
adapter, if the sleeve moves before the
quick disconnect adapter connector can
be connected to the charging valve,
move back the quick sleeve to its original
position and try again.
(3) When some refrigerant remains in the
charging hose at the time of connection,
it may be difficult to connect the quick
disconnect adapter. In this case, perform
the operation after removing any resid-
ual pressure in the hose.
Symbol Description
B Sleeve
C Click
DOIIC055R01105

/ 10 SERVICE AND REPAIR
Symbol Description
D Remove the residual pres-
sure by pushing the pusher
3. Removing the Quick Disconnect Adapter
While holding on the part “A” of the quick
disconnect adapter, slide part “B” up ⇒ re-
moval completed
CAUTION
After removing, make sure to cap the char-
ging valve.
Symbol Description
C Sleeve
D Click
DOIIC055R01106 4. Construction and Handling of Manifold
Gauge
By opening or closing the high and low
pressure hand valves, the following circuits
are made.
T When low pressure valve (LO) is open and

the high pressure valve (HI) is closed.
AF
Symbol Description
A Open
B Close
R
D
DOIIC055R01108
When the low pressure valve (LO) is closed

and the high pressure valve (HI) is open :
Symbol Description
A Close
B Open
DOIIC055R01107

SERVICE AND REPAIR / 11
When the low pressure valve (LO) is closed

and the high pressure valve (HI) is closed :
Symbol Description
A,B Close
DOIIC055R01109
5. New Gas Leak Detector for HFC 134a

The conventional gas leak detectors such as
the halide torch type and electronic type
cannot be used to detect a gas leak of HFC
134a.
Therefore, a new gas leak detector has been
T
developed to detect HFC 134a.
This new gas leak detector has a higher de-
gree of sensitivity to the presence of HFC
AF
134a.
Refrigerant
HFC 134a
Sens. mode
HI-SENS. 15 g (0.53 oz, 0.15 N)
to 30 g (1.06 oz, 0.3 N)
R
per year
R134a 40 g (1.41 oz, 0.4 N)
per year
D
DOIIC055R01111

6. Vacuum Pump Adapter

A vacuum pump can be used with HFC 134a
system by installing a vacuum pump adapter.
The vacuum pump adapter has two connect-
ing ports, one for HFC 134a system. Each of
these ports is connected to respective mani-
fold gauge of HFC 134a.
The vacuum pump adapter contains an intern-
al magnetic valve.
A : How to use
a. Connect the center charging hose (green)
to the proper connection port.
b. Using the plug cap, plug the other con-
nection port
c. Evacuate the system and close the mani-
fold gauge.
d. Turn off the vacuum pump.
B : Magnetic Valve Operation
T Symbol
A
Description
HFC 134a Connection port
(M10 x P1.5)
AF
B Plug cap
C Magnetic valve
DOIIC055R01112
D Vacuum pump
The vacuum pump adapter is used to
prevent the vacuum pump oil from
R
flowing back into HFC 134a system.

D

Without this adapter, after completing

the evacuation of the system, oil will flow
back into the manifold gauge hose by a
vacuum force in this hose when stopping
the vacuum pump.
a. When the switch of the vacuum pump is
turned on, the magnetic valve of the
adapter closes, starting the evacuation
of the system.
2. When the evacuation is completed and
the switch of the vacuum pump is turned
off, the magnetic valve opens, thus allow-
ing the introduction of air into the center
charging hose (green).
NOTE
Be sure to close the manifold gauge
valves immediately after evacuating the
system.
Then you may switch off the vacuum
pump.
T Symbol
A Open
Description
AF
B Close
C Atomospheric pressure
DOIIC055R01113
PRECAUTION FOR SERVICE
1. When handling the refrigerant (HFC 134a),
the following precaution must be observed.
R
• Do not handle the refrigerant in an enclosed

area or near an open flame.
• Always wear eye protection.
• Be careful that liquid refrigerant does not
D
get in your eyes or on your skin.

• If the liquid refrigerant gets in your eyes or
on your skin;
– Do not rub
– Wash the area with a lot of cool water
– Apply clean petroleum jelly to the skin
– Go immediately to a physician or hospital
for professional treatment.
– Do not attempt to treat yourself.

2. Recover refrigerant before replacing dry

parts using recovery machine.
Symbol Description
A Recovery machine
DOIQC055R12021
3. Insert a plug immediately into the disconnec-

ted parts to prevent entry of moisture and
dust.
Symbol Description
A Moisture
B Air
T C
D
Dust
Plug
AF
4. Do not leave a new condenser or receiver,
etc, where the plug is removed.
DOIIC055R01115 5. Do not use a burner for bending or lengthen-
ing operations on tubes.
6. If tubes are heated with a burner, a layer of
oxidation forms inside the tube, causing the
same kind of trouble as an accumulation of
R
dust.
7. Symbol Description
E Compressor oil
D
8. When tightening connecting parts;

• Apply a few drops of compressor oil to the
o-ring for easy tightening and prevent refri-
gerant gas from leaking.
• Do not over torque or loose the piping con-
nection as shown in the illustration.
DOIIC055R01116

• Symbol Description
F Over torque condition.
G Loose condition.
• Tightening the nut using two wrenches to
avoid the tube from twist.
CAUTION
Always use ZXL 100PG for DKS-17DS com-
pressor in HFC R134a refrigerant cycle.
• Tighten the O-ring fittings or the bottled
type fittings to the specified torque.
DOIIC055R01117
9. When handling refrigerant cylinder ;
• The refrigerant cylinder must never be
heated directly.
• The refrigerant cylinder must be kept below
40 °C (104 °F)
• If warming the refrigerant cylinder with hot
water, be careful that the valve on the top
of the refrigerant cylinder is never immersed
in the water, as the water may enter into the
T refrigerant cycle.
• Empty refrigerant cylinders must never be
re-used.
AF
10. When A/C is “ON” and the refrigerant gas is
being replenished;
• If there is not enough refrigerant gas in the
refrigerant cycle, oil lubrication becomes in-
sufficient and compressor burnout may occur,
so take care to avoid this.
R
• If the valve on the high pressure side is

opened with the engine running, the refri-
gerant flows in reverse and causes the refri-
gerant cylinder to rupture, so only open and
D
close the valve on the low pressure side.

• If the refrigerant cylinder is inverted and re-
frigerant is changed in a liquid state, the li-
quid is compressed and the compressor
breaks down, so the refrigerant must be
changed in a gaseous state.
• Be careful not to change too much refriger-
ant gas, as this causes troubles such as inad-
equate cooling, poor fuel economy, engine
overheating, etc.

ON-VEHICLE INSPECTION
1. Check condenser fans for blockage or dam-
age.
If the fins are clogged, wash the fins with
water.
CAUTION
Be careful not to damage the fins.
DOIHC055R04009
2. Make sure that fead belt is installed correctly.

Check that the fead belt are fits properly in
the ribbed grooves.
Symbol Description
A Correct
B Incorrect
T 3.
C
Start engine
Incorrect
AF
4. Turn on A/C switch
Check that A/C operates at each position of
DOIIC055R01119
the blower switch.
If the blower does not operate, check the
circuit breaker.
5. Check magnetic clutch operation.
If the magnetic clutch does not engage,
R
check the A/C fuse.

6. Check that idle increases.
When the magnetic clutch engages, engine
D
speed should increase.

Standard idle-up RPM : 1200 rpm
7. Check the condenser fan motor rotatation.
8. If there is no cooling or insufficient cooling,
inspect for leakage.
If the piping connections are soiled with oil,
it indicates leakage of refrigerant. Inspect by
the gas leak detector and retighten any loose
connectors.
IMPORTANT
Retightening the piping connection must be
done using two wrenches in order to avoid
twisting of the tubing .
9. Check the amount of refrigerant.
• Operate the air conditioner condition as
shown in the table below.
NOTE
When the ambient temperature is more than
40 °C (104 °F) and the pressure on the high

EVACUATING AND CHARGING / 17
pressure gauge becomes 19 kg/cm² (270.29

psi, 1.9 MPa) or more with the conditions
table shown, run the engine at the idling
speed to cool down the condenser.
If the high pressure gauge of manifold gauge
still indicates too high, perform this test in a
cool place, open all car doors and set the
blower speed to LO.
Item Condition
Doors Completely opened
Temperature setting Maximum cooling
Mode Face
Blower speed HI
Recirculation / Fresh air change Recirculation air
Engine speed HFC 134a ⇒ 1500 rpm
A/C ON
EVACUATING AND CHARGING
T TROUBLESHOOTING PROCEDURE
WCH055SPROC11004
AF
For Evacuating and Charging troubleshooting
procedures, please refer to Supplier's Cooler Unit
System Manual
CAUTION IN HANDLING THE
REFRIGERANT
R
1. When handling refrigerant, the following

precautions must be observed.
1.1 Always wear eye protection while
handling refrigerant.
D
1.2 The refrigerant cylinder must never be

heated. Store the refrigerant cylinder
below 40 °C (104 °F).
1.3 Do not handle refrigerant in an en-
closed area where it is exposed to an
open flame.
1.4 Protect eyes and skin from refrigerant.
2. If refrigerant strikes eyes or skin
2.1 Do not rub the affected areas.
2.2 Splash large quantities of cool water on
the eyes or skin.
2.3 Do not attempt to treat the patient by
yourself. Rush the patient to a doctor
or hospital for immediate professional
treatment.

/ 18 EVACUATING AND CHARGING
AIR-COND SERVICE TOOL

1. Installation of Manifold Gauge
1.1 Close both high and low hand valves.
1.2 Connect the low pressure hose to the
low pressure charging valve and the
high pressure hose to the high pressure
charging valve. Tighten the hose nuts
by hand.
IMPORTANT
Do not apply compressor oil to the
seats of the connections.
DOIQC055R12005
Symbol Description
A Close valve button
B High pressure charging
valve
C Low pressure charging
valve
2. Evacuate air in Refrigerant System
T Symbol
A
Procedures
Open high and low pressure
AF
valves
B Air movement
2.1 Connect the center hose of the gauge
set to the vacuum pump inlet.
2.2 Open both the high and low hand
valves and run the vacuum pump.
R
If opening the low pressure hand valve,

pulls the high pressure gauge into the
vacuum range (there is no blockage in
D
the system.)
2.3 After about 20 minutes or more, check
that the low pressure gauge shall indic-
ates more than 80.0 kPa (11.38 psi,
24.15 in.Hg) of vacuum.
If the reading is not more than 80.0 kPa
(11.38 psi, 24.15 in.Hg), close both
valves and stop the vacuum pump.
Check the system for leaks and repair
as necessary.
2.4 If no leak is found, continue evacuating
the air in the system.
DOIGC055R03001
2.5 Continue evacuating the air in the sys-
tem until the low pressure gauge indic-
ates a vacuum of 99.98 kPa (14.22 psi,
30.18 in.Hg).
2.6 Close both the high and low hand
valves and stop vacuum pump. Then,
leave the system in this condition for
five minutes or longer and check that

EVACUATING AND CHARGING / 19
there is no change in the gauge indica-

tion.
3. Installation Connector to Gas Cylinder
3.1 Make sure the cylinder is up position
for gas charging.
3.2 Open the valve at the top of the cylin-
der.
3.3 Press on the schrader valve on the side
of the manifold gauge set and expel
the air from inside the center hose.
HINT:
Press on the schrader valve until the
refrigerant is comes out.
Symbol Procedures
A Close ⇒ High and Low
pressure valve
B Open ⇒ cylinder valve
C Press ⇒ schrader valve
T
AF
DOIGC055R03002
R
D

/ 20 EVACUATING AND CHARGING
4. Inspect Refrigeration System for leakage.

NOTE
After evacuating the air in the system, check
the system for leakage.
4.1 Open the high pressure hand valve to
charge the system with refrigerant va-
por.
NOTE
When the refrigerant cylinder is placed
rightside up, refrigerant will enter the
system as a vapor.
4.2 When the low pressure gauge indicates
1 kg/cm² (14.23 psi, 0.1 MPa), close the
high pressure hand valve.
4.3 By using gas leak detector, check the
system for leakage.
4.4 If a leak is found, repair the faulty
component or connection.
Symbol Description
T A
B
Low pressure valve
High pressure valve
AF
DOIGC055R03003
5. Charge the empty Refrigerant System with

refrigerant (Liquid).
R
NOTE
This step is used to change an empty system
through the high pressure side with refriger-
ant in a liquid state. When the refrigerant
D
cylinder is held upside down, refrigerant will

enter the system as a liquid.
Symbol Procedures
A Close ⇒ Low pressure valve
B Refrigerant cylinder is held
upside down
D Fully open
CAUTION
• Never run the engine when charging the
system through the high pressure side.
• Do not open the low pressure hand valve
when the system is being charged with
liquid refrigerant.
5.1 Open the high pressure hand valve fully
and keep the refrigerant cylinder upside
down.
DOIGC055R03004

6. Charge partially the Charged System with

Refrigerant (Vapor)
NOTE
• This step is used to charge the refrigerant
system through the low pressure side
with the refrigerant in vapor state. When
the refrigerant cylinder is placed right-
side up, refrigerant will enter the system
as a vapor.
6.1 Open the low pressure valve. Adjust the
valve, so that the low pressure gauge
does not read over 4.2 kg/cm² (59.75
psi, 0.42 MPa).
6.2 Run the engine at fast idle and operate
the air conditioner.
Symbol Procedures
D Open ⇒ Low pressure valve
E Close ⇒ High pressure
valve
T CAUTION
Be sure to keep the refrigerant cylinder
AF
in the upright position to prevent the
liquid refrigerant from being intro-
duced into the refrigerant system
DOIGC055R03005
through the suction side, resulting in
possible damage to the compressor.
7. Remove Manifold Gauge Set
7.1 Close both the high and low hand
R
valves.
7.2 Close the valve at the refrigerant cylin-
der.
D
7.3 Turn off the engine.

7.4 Quickly disconnect the three hoses from
the service valves of the system and the
container tap valve.
7.5 Put cap nuts on the service valve fit-
tings.
RECEIVER DRIER TEST

1. Operate the unit and check the piping tem-
perature by touching the receiver drier outlet
and inlet. If there is difference in the temper-
atures, the receiver drier is restricted. Replace
the receiver drier.

DUAL PRESSURE SWITCH CHECK

1. Remove the dual pressure switch connector
and connect the high/low pressure side (A)
terminals located on the harness side as
2. Install a gauge manifold to the high pressure
side service valve of the refrigerant line
(Refer to Performance Test Procedures).
3. When the high/low pressure sides of the dual
pressure switch are at operation pressure
(ON) and there is continuity between the
respective terminals, then the condition is
normal. If there is no continuity, replace the
switch.
T
AF
DOIQC055R12006
Items Switch position

OFF(2) → ON(1) ON(1) → OFF(2)
R
Low-pressure side (B) 221 kPa (31.44 psi, 66.72 196 kPa (27.88 psi, 59.17 in.Hg)
in.Hg)
High-pressure side (C) 2550 kPa (362.76 psi, 3138 kPa (446.41 psi, 947.3 in.Hg)
D
769.79 in.Hg)

PERFORMANCE TEST WCH055SPROC11006
1. The vehicles to be tested should be in a place

that is not in direct sun light.
2. Close the high (C) and low (B) pressure valve
of the gauge manifold, (D).
3. Connect the charging hose “G” (blue) to the
low pressure valve and connect the charging
hose “V” (red) to the high pressure of the
gauge manifold.
4. Install the Quick joint “O” (for low pressure)
to the charging hose “G” (blue), and connect
the Quick joint “O” (for high pressure) to the
charging hose “V” (red).
5. Connect the quick joint (for low pressure) to
the low-pressure service valve (N) and con-
nect the quick joint (for high pressure) to the
high-pressure service valve (W).
NOTE
The high-pressure service valve (W) is on pipe
T liquid B and the low-pressure service valve

(N) is on the suction hose.
CAUTION
AF
To connect the quick joint, press'A' firmly
against the service valve until a click sound
DOIIC055R9015
is heard.
6. Start the engine.

7. Set the controls to the A/C as follows:
A/C switch: A/C–ON position
R
Mode selection: Face position

Temperature control: Max. cooling position
Air selection: Recirculation position
D
Blower switch: HI (Fast) position

8. Adjust engine speed to 1500 rpm with A/C
clutch is engaged.
9. Engine should be warmed up with doors and
windows are closed.
10. Insert a digital thermometer (X) in the left
DOIQC055R12007 center A/C outlet and operate the engine for
20 minutes.
Standard Value :-
PATCO
Ambient at 30 - 35 °C (86 - 95 °F) ⇒ Outlet 6
- 8 °C (42.8 - 46.4 °F)
11. Note the discharge air temperature.

NOTE
If the clutch cycles, take the reading before
the clutch disengages.

REFILLING OF OIL IN THE A/C SYSTEM WCH055SPROC11007
Too little oil will provide inadequate compressor lubrication and cause a compressor failure. Too much
oil will increase discharge air temperature.
When a compressor is installed at the factory, it contains 200 - 220 cm³ (12.2 - 13.42 cu.in) of refrigerant
oil. While the A/C system is in operation, the oil is carried through the entire system by the refrigerant.
Some of this oil will be trapped and retained in various parts of the system.
When the following system components are changed, it is necessary to add oil to replace the oil being
removed with the component.
Items Specified lubricants / Quantity

Compressor oil APM CC ZXL 100PG
Standard value 200 - 220 cm³ (12.2 - 13.42 cu.in)
Items Quantity
Condenser 30 cm³ (1.83 cu.in)
Evaporator 30 cm³ (1.83 cu.in)
Suction hose / Discharge hose / Piping 30 cm³ (1.83 cu.in)
Receiver 30 cm³ (1.83 cu.in)
REFRIGERANT LEAK REPAIR

LOST CHARGE
T WCH055SPROC11008
AF
If the system has lost all charge due to a leak:
1. Charge the system with approximately 200 cm³ (12.2 cu.in) of refrigerant.
2. Check for leaks.
3. Discharge the system.
4. Repair leaks.
5. Replace receiver drier.
R
CAUTION
Replacement filter-drier units must be sealed while in storage. The drier used in these units will
saturate water quickly upon exposure to the atmosphere. When installing a drier, have all tools
and supplies ready for quick reassembly to avoid keeping the system open any longer than ne-
D
cessary.
LOW CHARGE
If the system has not lost all of its refrigerant charge, locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak (because of an especially low charge) add refrigerant. If
it is possible to repair the leak without discharging the refrigerant system, use the procedure for
correcting low refrigerant level.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are produced in the system when it is operating.
Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture
can enter the system when it is opened for repair or replacement of lines or components. The following
precautions must be observed. The system must be completely discharged before opening any fitting
of connection in the refrigerant system. Open fittings with caution even after the system has been
discharged. If any pressure is noticed as a fitting is loosened, allow trapped pressure to bleed off very
slowly.
Never attempt to rebend formed lines to fit. Use the correct line for the installation you are servicing.
A good rule for the flexible hose lines is keep the radius of all bends at least 10 times the diameter
of the hose.

Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so that
they are at least 80 mm (3.15 in) from the exhaust manifold. It is good practice to inspect all flexible
hose lines at least once a year to make sure they are in good condition and properly routed.
Unified plumbing connections with O-rings, these O-rings are not reusable.
COMPRESSOR NOISE WCH055SPROC11009
You must first know the conditions when the noise occurs. These conditions are: weather, vehicle
speed, in gear or neutral, engine temperature or any other special conditions.
Noises that develop during A/C operation can often be misleading. For example: what sounds like a
failed front bearing or connecting rod, may be caused by loose bolts, nuts, mounting brackets, or a
loose clutch assembly. Verify accessory fead belt tension (power steering or alternator).
Improper accessory fead belt tension can cause a misleading noise when the compressor is engaged
and little or no noise when compressor is disengaged.
Speed belts are speed-sensitive. That is, at different engine speeds, and depending upon belt tension,
belt can develop unusual noises that are often mistaken for mechanical problems within the compressor.
ADJUSTMENT
1. Select a quiet area for testing. Duplicate conditions as much as possible. Switch compressor on
and off several times to clearly identify compressor noise. To duplicate high ambient conditions
(high head pressure), restrict air flow through condenser. Install manifold gauge set to make sure
T
discharge pressure doesn't exceed 2070 kPa (294.48 psi, 624.89 in.Hg).
2. Tighten all compressor mounting bolts, clutch mounting bolt, and compressor fead belt. Check
to assure clutch coil is tight (no rotation or wobble).
AF
3. Check refrigerant hoses for rubbing or interference that can cause unusual noises.
4. Check refrigerant charge. (See Charging System )
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mounting bolts and retorque. Repeat Step 1.
7. If noise continues, replace compressor and repeat Step 1.
R
D

POWER RELAY CHECK

BLOWER RELAY
Symbol Description
A Blower relay
T
AF
DOIQC055R12020
PCB RELAY A/C COMPRESSOR BUILT-IN

Symbol Description
R
B Pcb relay compressor built –

in
D
DOIQC055R12022

AIR-COND CONTROL ASSEMBLY / 27
AIR-COND CONTROL ASSEMBLY WCH055SASSY11003
T
AF
R
D
DOIQC055R12002

/ 28 AIR-COND CONTROL ASSEMBLY

• Center cover removal and installation (Refer to GROUP-52A)
Removal steps
1. Center cover
2. Screw
3. Control assembly ventilator
T
AF
R
D

CONTROL ASSY VENTILATOR / 29
CONTROL ASSY VENTILATOR

WCH055SPROC11010
INSPECTION SERVICE POINT

SPECIFICATION FOR CONTROL ASSY VENTILATOR
1. The specification of FAN switch connector
terminal number and name.
Step Circuit Mate

OFF (GRN) Terminal No. 4
LOW Terminal No. 4 ⇒ Terminal
No. 5 ⇒ Terminal No. 1
M/L Terminal No. 4 ⇒ Terminal
M/H Terminal No. 4 ⇒ Terminal
HIGH Terminal No. 4 ⇒ Terminal
COM Terminal No. 5
T
AF
DOIQC055R12003
2. The specification of MODE connector termin-

al number and name.
R
No Name
1 IG2
2 Foot
D
3 Vent
4 GND
5 —
6 PBR
7 Vref
DOINC055R09048

/ 30 CONTROL ASSY VENTILATOR
3. The specification of MAIN connector terminal

number and name.
No Name
1 —
2 IG2
3 ILL –
4 ILL +
5 GND
6 —
7 FRE
8 REC
9 A/C SIGNAL
10 TEMP
11 MAX COOL
12 FAN
T
AF
DOIQC055R12004
R
D

COOLER ASSY UNIT AND BLOWER ASSY UNIT / 31
COOLER ASSY UNIT AND BLOWER ASSY UNIT WCH055SASSY11004
T
AF
R
DOIQC055R11001
D
Pre-removal and Installation

• Instrument panel (Refer to GROUP 52A – Instrument Panel Assembly.
• Disconnect battery
• Suction pipe connection
• Pipe liquid B connection
CAUTION
Cooler unit removal steps
1. Cooler assy unit
2. Blower assy unit
T1:0.4 - 0.6 kgm (4 - 6 Nm, 2.89 - 4.34 ft.lbs)
Note:
The blower filter and blower motor can be removed without removing of the instrument panel assy
(refer to page 55/32 – On Vehicle Service)

/ 32 COOLER ASSY UNIT
COOLER ASSY UNIT WCH055SPROC11011

COOLER UNIT ASSY AND BLOWER UNIT ASSY
REMOVAL
1. Unscrew 4 pieces nut top side which attach-
ing at the cooler unit and blower unit.
2. Remove 4 pieces nuts below that attached
to the cooler unit and blower unit respect-
ively to the car body.
3. Remove the drain hose from the cooler unit.
4. Remove the blower unit first and then re-
move the cooler unit.
Symbol Description
A Blower unit
B Cooler unit
T BLOWER FILTER COVER REMOVAL

1. Remove the glove box cover (Refer to GROUP
AF
-52A INTERIOR)
DOIQC055R12008
2. Remove blower filter cover and remove the

blower unit.
R
Symbol Description
A Filter cover
D
DOIQC055R12009
BLOWER MOTOR
1. Disconnect blower motor connector.
2. Remove 3 pieces blower motor screws as
DOIQC055R12010

MAIN FUNCTIONAL COMPONENTS / 33
3. Remove the blower motor.
Symbol Description
A Blower motor
DOIQC055R12011

BLOWER MOTOR INSTALLATION
1. Insert the blower motor in blower case by
adjusting to the respective pin locks.
T
Symbol Description
A Pin lock
AF
DOIQC055R12012
MAIN FUNCTIONAL COMPONENTS

WCH055SPROC11013
THERMO AMP SENSOR

R
The thermo amp sensor, which mounted at the

rear side of the evaporator in the air conditioner
unit, detects the air temperature of the evapor-
D
ator.
Symbol Description
A 11 row from right
B 120 mm (4.72 in) ± 1 mm (0.039
in)
C Thermo amp sensor
The characteristics and electrical circuitry to the
computer are the same as the room temperature
sensor.
DOINC055R09003

/ 34 MAIN FUNCTIONAL COMPONENTS
THERMO AMPLIFIER
1. Electronic device containing a circuit board
and electrical components.Thermistor resist-
ance is amplified and used to control or
switch the compressor clutch ON and OFF.
Temperature Control range:

4.5 °C (40.1 °F) ± 0.5 °C (32.9 °F), VR
Off point
= 0 kΩ
17.5 °C (63.5 °F) ± 2.0 °C (35.6 °F) ,
Off point
VR = 10 kΩ
DOIMC055R07005 Symbol Description
A Thermo amplifier
RESISTOR
1. Use circuit tester to measure the resistance
between the terminal as indicated in the
table.Check that the measured value is
within the standard value
T Symbol
Front
Description
Rear
AF
Between ter-
1.34 Ω 2.22 Ω
minal 1 and 2
Between ter-
1.9 Ω 3.34 Ω
DOINC055R08001 minal 1 and 3
Between ter-
2.23 Ω 4.05 Ω
minal 1 and 4
R
D

COOLER ASSY UNIT / 35
COOLER ASSY UNIT WCH055SASSY11005
T
AF
R
DOIQC055R12016
D
Cooler unit assy removal steps

1. Case heater and air cond driver 11. Parking air distributor 2
2. Case heater and a/c ast 12. Cap aspirator
3. Door assy def 13. Duct foot door
4. Door assy vent 14. Motor actuator mode
5. Door assy foot 15. Main link mode
6. Center cover 16. Panel cooler case
7. Sub harness air cond 17. Duct foot ast 1
8. Hose drain assy 18. Duct foot ast 2
9. Grommet exp valve 19. Packing case 1
10. Parking air distributor 1 20. Evaprator and sub pipe comp assy

/ 36 REFRIGERANT LINE
REFRIGERANT LINE WCH055SASSY11006
T
AF
R
DOIQC055R12001
D

• Discharging and charging of refrigerant (Refer to page 55/17 ).
• Front Bumper (Refer to GROUP 51 EXTERIOR).
• Master cylinder and brake booster (Refer to GROUP 35B SERVICE BRAKE).
Compressor oil: APM CC ZXL 100PG

– Non-reusable parts
Removal steps
1. Suction flexible hose
2. O-ring
3. Pipe suction
4. Discharge flexible hose
5. Pipe liquid A
6. Dual pressure switch
7. Pipe liquid B

REFRIGERANT LINE / 37
T1 : 2.9 - 3.4 kgm (29 - 34 Nm, 20.98 - 24.59 ft.lbs)

T2 : 1.2 - 1.5 kgm (12 - 15 Nm, 8.68 - 10.85 ft.lbs)
T3 : 0.4 - 0.6 kgm (4 - 6 Nm, 2.89 - 4.34 ft.lbs)
T
AF
R
D

/ 38 REFRIGERANT LINE FRONT
REFRIGERANT LINE FRONT

WCH055SPROC11014

PIPE LIQUID B AND PIPE SUCTION DISCON-
NECTION
1. Disconnect pipe liquid A from pipe liquid B.
2. Disconnect suction flexible hose from pipe
suction.
3. Disconnect both pipe suction and pipe liquid
B from evaporator.
Symbol Description
A Pipe suction
B Pipe liquid B
4. Remove both pipe suction and pipe liquid B.
If required, the suction flexible hose can be
removed by disconnecting the other end that
attached to the air cond compressor.
DOIQC055R12013
T CAUTION
Plug or seal completely the disconnected
pipelines and hoses in order to prevent foreign
AF
materials (e.g. water vapour) get into the pipe
lines and hoses.
PIPE LIQUID B AND PIPE SUCTION INSTALLA-
TION
R
Installation of pipe liquid B and pipe suction can

be done by reversing the removal process. When
replacing the suction flexible hose refill with a
specified amount of compressor oil.
D
Use air cond compressor oil to lubricate all o-

rings.
Compressor oil:
APM CC ZXL 100 PG
Items Quantity
Suction hose 30 cm³ (1.83 cu.in)

AIR COND COMPRESSOR (CFE) / 39
AIR COND COMPRESSOR (CFE) WCH055SASSY11007
T
AF
R
D
DOIQC055R12014

/ 40 AIR COND COMPRESSOR (CFE)
• Discharging of refrigerant (Refer to page WCH055SPROC094.)
• Charging of refrigerant (Refer to page WCH055SPROC092.)
Compressor oil: APM CC ZXL 100 PG.

PC — Piping connection
Non-reusable part
Removal steps
1. Fead belt
3. Suction flexible hose
4. Discharge flexible hose
5. O-ring
6. Air cond compressor
T
T1 :2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T2 :4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)
T3 :0.4 - 0.6 kgm (4 - 6 Nm, 2.89 - 4.34 ft.lbs)
AF
R
D

COMPRESSOR / 41
COMPRESSOR WCH055SPROC11015

FEAD BELT REMOVAL
1. Insert ratchet (A) into square hole at fead
belt tensioner.
DOIGC11AR03025
2. Push the ratchet (A) towards engine intake

side and remove the fead belt from the al-
ternator.
T
AF
DOIGC11AR03026
SUCTION FLEXIBLE HOSE AND DISCHARGE

FLEXIBLE HOSE DISCONNECTION
R
Plug the disconnected hoses and the air cond

compressor nipple in order to prevent foreign
materials get into the hoses and nipple.
D
CAUTION
Seal completely the hoses, otherwise the com-
pressor oil and receiver will absorb water vapour
easily.
DOINC055R09035
COMPRESSOR REMOVAL
During performing this removal, be careful not
to spill the compressor oil.
1. Disconnect compressor switch connector as
COMPRESSOR INSTALLATION
If a new compressor is installed, first adjust the
amount of oil according to the procedures de-
scribed below, and then install the compressor.
1. Measure the amount (X cm³) of oil within
the removed compressor.

/ 42 COMPRESSOR
2. Drain (from the new compressor) the amount

of oil calculated according to the following
formula, and then install the new com-
pressor. New compressor oil amount
135 cm³ (8.24 cu.in) – X cm³ = Y cm³.
NOTE
(1) Y cm³ indicates the amount of oil in the
refrigerant line, the condenser, the
evaporator and etc.
(2) When replacing the following parts at
the same times, subtract the rated oil
amount of the each part from Y cm³ and
discharge from the new compressor.
Quantity : <PATCO>
Items Quantity
Evaporator 30 cm³ (1.83 cu.in)
Condenser 30 cm³ (1.83 cu.in)
Suction hose 30 cm³ (1.83 cu.in)
30 cm³ (1.83 cu.in)
T Receiver
12.5- 13.5 V
AF
INSPECTION
COMPRESSOR MAGNETIC CLUTCH OPERATION
INSPECTION
Connect the battery (+) terminal to the com-
pressor side terminal, and earth the battery (-)
terminal to the body of the compressor. The
R
condition is normal if the click sound of the

magnetic clutch can be heard.
D
DOINC055R08024

CONDENSER AND CONDENSER FAN MOTOR / 43
CONDENSER AND CONDENSER FAN MOTOR WCH055SASSY11008
T
AF
R
DOIQC055R12017
D

• Front bumper removal and installation (Refer to GROUP – 051 EXTERIOR)
Condenser fan motor removal steps Condenser removal steps
1. Radiator upper hose 9. Tank assy condenser
2. Bracket assy insulator upper RH 10. Hose assy tank condenser
3. Bracket assy insulator upper LH 11. Bracket upper
4. Clip 12. Bracket lower
5. Radiator lower hose 13. Receiver drier
6. Hose radiator condenser tank 14. Condenser assy
7. Fan motor shround assy 15. Front end module
8. Radiator assy
T1 : 1.0 - 1.4 kgm (10 - 14 Nm, 7.23 - 10.13 ft.lbs)
T2 : 0.9 - 1.4 kgm (9 - 14 Nm, 6.51 - 10.13 ft.lbs)
T3 : 0.59 - 0.83 kgm (5.9 - 8.3 Nm, 4.27 - 6 ft.lbs)

/ 44 CONDENSER AND CONDENSER FAN MOTOR
FAN MOTOR SHROUD REMOVAL

1. Remove tank assy condenser hose.
Symbol Description
A Tank assy condenser
DOIQC055R12033
2. Remove coolant hose turbo charger and

lower hose radiator.
Symbol Description
B Hose assy turbo charger
C Radiator lower hose
T
AF
DOIQC055R12034
RADIATOR ASSY REMOVAL

1. Drain coolant from plug assy
R
D
DOIQC055R12024
2. Remove 2 pieces upper bolts of radiator assy

Symbol Description
A Bracket assy insulator upper
DOIQC055R12025

CONDENSER AND CONDENSER FAN MOTOR / 45
3. Remove radiator hose coolant and lower

hose
DOIQC055R12026
4. Disconnect blower motor
T
AF
DOIQC055R12027
5. Remove condenser fan bolt

R
D
DOIQC055R12028
6. Slowly and carefully remove the radiator assy

from engine room.
DOIQC055R12029

/ 46 CONDENSER AND CONDENSER FAN MOTOR
CONDENSER ASSY REMOVAL

1. Remove 2 pieces bolts of pipe liquid A, and
then release the pipe suction from the pipe
assy.
Symbol Description
A Pipe liquid A bolt
DOIQC055R12030
2. Slightly and carefully push the radiator assy

to the engine side closely.
3. Remove the condenser in between the radi-
ator assy and front end module (FEM).
Symbol Description
B Condenser assy
T
AF
DOIQC055R12031
CONDENSER ASSY INSTALLATION

When replacing the condenser, refill the pipe li-
R
quid A and pipe suction with a specified amount

of compressor oil.
Compressor oil :
APM CC ZXL 100PG
D
Quantity :
30 cm³ (1.83 cu.in)
Symbol Description
DOIQC055R12031
B Condenser assy
INSPECTION
CONDENSER FAN AND MOTOR CHECK
Check the condenser fan motor operation when
battery voltage is applied to terminal 1 and ter-
minal 2 to earth..
Symbol Description
1 Red (applied to terminal)
2 Black (earth)
3 Motor wire and connector
DOIQC055R12032

VENTILATORS / 47
VENTILATORS WCH055SASSY11009
FRONT DUCT
T
AF
R
DOIQC055R12018
D

• Instrument Panel removal and installation (Refer to GROUP 52A INTERIOR).
Defroster duct and distribution duct removal steps
Removal steps
1. Instrument panel finisher , passenger side RH
2. Cover meter combi LH
3. Duct, side defroster RH.
4. Duct, side defroster LH
5. Duct ,assy front ventilation
6. Duct, centre defroster
7. Instrument panel
8.

/ 48 VENTILATORS
REAR DUCT
T
AF
R
DOIQC055R12019
D

• Rear bumper (Refer to GROUP 51 EXTERIOR).
Defroster duct and distribution duct removal steps
Removal steps
1. Ventilator duct RH,LH
2. Rear side structure

WORKSHOP MANUAL ALL
Index /1
ABS-ECU...................................................... 35C/67
Air Bag............................................................. 00/4
Diagnosis Code........................................... 35C/10
T
AF
R
D

D
R

AF
T
WORKSHOP MANUAL
ENGINE OVERHAUL
S4P
Model YR 2011
English Edition RDCE-110S4P020-04
Destination: ALL
November 2011 Printed in Malaysia
Copyright ©
Perusahaan Otomobil
Nasional Sdn. Bhd.
Printed in Malaysia 30 November 2011 Eng
WORKSHOP MANUAL -
Group Index /I
00 GENERAL ................................................................................... 00/1 - 00/14

11A ENGINE <S4P-CFE> ............................................................... 11A/1 - 11A/122

- WORKSHOP MANUAL
/ II Group Index
NOTE

GENERAL 00
Content /1
00 GENERAL
OUTLINE OF CHANGES ............................................................... 00/2
DESCRIPTION ......................................................................... 00/2
TABLE OF CHANGE ITEMS & REFERENCE MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
OUTLINE OF CHANGE ITEMS ..................................................... 00/5
AIR BAG SYSTEM INFORMATION .................................................. 00/6

WARNING ............................................................................ 00/6

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
DEFINITION OF TERMS ............................................................ 00/7
STANDARD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
REFERENCE VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/7
ENGINE MODEL AND SERIAL NUMBER LOCATION ............................. 00/11
TIGHTENING TORQUE ................................................................ 00/11

STANDARD PARTS TIGHTENING TORQUE ...................................... 00/11
TIGHTENING TORQUE OF FLANGE BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/11
TIGHTENING TORQUE OF BOLT (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/11
TIGHTENING TORQUE OF FLANGE NUT (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/12
TIGHTENING TORQUE SCREW (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/12
TIGHTENING TORQUE STUD (SPECIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/12
PRECAUTION BEFORE SERVICE ..................................................... 00/12

00 GENERAL
/2 OUTLINE OF CHANGES
OUTLINE OF CHANGES WEO000OLINE11001
DESCRIPTION
This bulletin updates information on CamPro engine and is additional supplement to WORKSHOP
MANUAL ENGINE OVERHAUL Pub. No: RDCE-08OS4P020–00 (CamPro Basic) and RDCE-08OS4P020–04
(CamPro-CFE) which contains changes/modifications/updates/additional information due to the intro-
duction of Charged Fuel Efficient (CFE) fitted on CamPro engine.
TABLE OF CHANGE ITEMS & REFERENCE MANUALS
This table indicates those changes and/or addition, etc. have been made; the change items are listed
in the sequence in which they are presented in this bulletin. Please use this table for reference when
performing repair or overhaul procedures which related to CamPro-CFE engine.
LEGEND :
: The symbol indicates a system which is no changes has been made and the information is
not in this supplement manual. The respective item/system should be referred to the pre-
vious supplement or/and basic manual.
: The symbol indicates a system which a changes and/or addition has been made and the
information is presented in this supplement manual.
: The symbol indicates a system is not equipped in the vehicle of the respective manual
(Basic or Supplement).
PUB. NO: RDCE-080S4P020 –
CHANGE CLASSIFICATION BASIC BULLETIN
00 01 02 03 04 (NEW)
GRP 00 – GENERAL
CamPro
CamPro-CPS
Engine & Transmis-
CamPro - IAFM
sion Model
CamPro-IAFM+
CamPro-CFE
Engine Model &
Serial Number Loc- –
ation
GRP 11A- ENGINE <S4P>
CamPro
CamPro-CPS
Specifications CamPro-IAFM
CamPro-IAFM+
CamPro-CFE

GENERAL 00
OUTLINE OF CHANGES /3

00 01 02 03 04 (NEW)
CamPro
CamPro-CPS
Special tools CamPro-IAFM
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Alternator and igni-
CamPro-IAFM
tion system
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Timing belt CamPro-IAFM
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Fuel and emission
CamPro-IAFM
control system
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Water pump and
CamPro-IAFM
water hose
CamPro-IAFM+
CamPro-CFE

00 GENERAL
/4 OUTLINE OF CHANGES

00 01 02 03 04 (NEW)
CamPro
CamPro-CPS
Intake and exhaust
CamPro-IAFM
manifold
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Camshaft and tap-
CamPro-IAFM
pet
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Cylinder head and
CamPro-IAFM
valve
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Oil pump and oil
CamPro-IAFM
pan
CamPro-IAFM+
CamPro-CFE
CamPro
CamPro-CPS
Piston and connect-
CamPro-IAFM
ing rods
CamPro-IAFM+
CamPro-CFE

GENERAL 00
OUTLINE OF CHANGES /5

00 01 02 03 04 (NEW)
CamPro
CamPro-CPS
Crankshaft and cyl-
CamPro-IAFM
inder block
CamPro-IAFM+
CamPro-CFE
OUTLINE OF CHANGE ITEMS

GRP 11A–ENGINE <S4P-CFE>
Change Items Reference Page Description of Changes
Special Tools • New special tools for CamPro-
11A/10
CFE engine overhaul
Alternator and Ignition System • New design, procedure spark
• Installation service points plug for CamPro-CFE engine.
– Spark plug • New design, procedure cam
– Cam shaft sensor position sensor for CamPro-CFE
– Oil control valve 11A/14 engine.
• Additional part is included to
correspond with the CamPro-CFE
engine – Oil control valve.
Fuel and Emission Control System

• New design fuel rail assy for
• Removal service points 11A/25
CamPro-CFE engine.
– Fuel rail assy
Intake Manifold
• New design intake manifold for
• Removal and installation service points 11A/28
CamPro-CFE engine.
– Intake manifold
Exhaust Manifold • New design, procedure and
graphic for CamPro-CFE engine
• Removal and installation service points
is included.
– Turbocharger heatshield bracket
• Additional part is included to
– Exhaust manifold heatshield
– Exhaust manifold 11A/31 engine – Turbocharger assy, tur-
– Brace support bracket
bocharger heatshield bracket,
– Turbocharger assy
brace support bracket, recircula-
– Recirculation pump
tion pump, oil drain pipe and oil
– Oil drain pipe
feed pipe.
– Oil feed pipe
Timing Belt • New design, procedure and
• Removal and Installation service points graphic for CamPro-CFE engine
11A/41
is included – VVT sprocket and
mechanical tappet.

00 GENERAL
/6 AIR BAG SYSTEM INFORMATION
Change Items Reference Page Description of Changes

Water Pump and Water Hose • Additional part is included to
• Removal and installation service points 11A/51 correspond with the CamPro-CFE
– Oil cooler engine – Oil cooler.
Cylinder Head and Valves • Additional special tool is in-
cluded to correspond with the
• Removal and Installation
CamPro-CFE engine – Cylinder
– Tappet
head valve jig.
11A/77
• New procedure for removal and
installation CamPro-CFE engine
is included – Mechanical tappet
and cylinder head
Oil Pump and Oil Pan • Additional part is included to
• Removal and Installation 11A/88 correspond with the CamPro-CFE
– Windage tray engine – Windage tray.
Piston and Connecting Rods
• Installation & removal service points • New design, procedure and
– Piston 11A/96
graphic for CamPro-CFE engine.
– Connecting rod
– Piston pin and piston pin circlip
Crankshaft and Cylinder Block • New design, procedure and
graphic for CamPro-CFE engine.
• Removal and Installation service points
11A/109 • Additional part is included to
– Direct damper flywheel <CVT3>
– Crankshaft assy
engine – Oil jet.
– Oil jet
AIR BAG SYSTEM INFORMATION WEO000BSERV11001
This vehicle has an air bag system which will supplement the seat belt in certain frontal collisions. The
air bag is not a substitute for the seat belt in any type of collision. The drivers and all other occupants
should wear seat belts at all times. Warning if the “SRS” warning light does not illuminate for several
seconds when the ignition key is turned to “ON” or the engine is started or if the warning light stays
on while driving, take the vehicle to your nearest authorized dealer immediately. Also if the vehicle's
front end is damaged or if the airbag has deployed, take the vehicle for service immediately. The air
bag system must be inspected by an authorized dealer ten years after the date of vehicle registration.
Read the “SRS” section of your owner's manual before driving for important information about op-
eration and service of the air bag system. When you are going to discard your gas generator or vehicle,
please see your dealer.
WARNING
(1) Improper service or maintenance of any component of the SRS or any SRS —related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air bag)
or to the driver and passenger (from rendering the SRS inoperative.)
(2) SRS components should not be subjected to heat over 85 °C (185 °F) , so remove the SRS-ECU, air
bag module and clock spring before drying or baking the vehicle after painting.
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized dealer.
(4) Dealer personnel must thoroughly review Chassis Manual, and especially its GROUP 52B - Supple-
mental Restraint System (SRS), before beginning any service or maintenance of any component
of the SRS or any SRS-related component.

GENERAL 00
NOTE :
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring
warnings.
HOW TO USE THIS MANUAL WEO000READS11001

This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however, that for engine and transmission-related component
parts, this manual covers only on-vehicle inspections, adjustments and the removal and installation
procedures for major components. For detailed information concerning the inspection, checking, ad-
justment, disassembly and reassembly of the engine, transmission and major components after they
have been removed from the vehicle, please refer to separate manuals covering the engine and the
transmission.
ON-VEHICLE SERVICE
“On-Vehicle Service” is a procedure for performing inspections and adjustments of particularly import-
ant locations with regard to the construction and for maintenance and servicing, but other inspections
(for looseness, play, cracking, damage and etc.) must also be performed.
INSPECTION
Under this title are presented inspection and checking procedures to be performed by using special
tools and measuring instruments and by feeling but for actual maintenance and servicing procedures,
visual inspections should always be performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value as the standard for judging the quality of a part of assembly on inspection or the
value to which the part or assembly is corrected and adjusted. It is given by tolerance.
LIMIT
It is a value established outside the range of standard value.
REFERENCE VALUE
CAUTION :
The tightening torque shown in this manual is a basic value with a tolerance of ±10% except the fol-
lowing cases when the upper and lower limits of tightening torques are given.
1. The tolerance of the basic value is within ±10%
2. Special bolts or nuts are in use.

00 GENERAL
/8 HOW TO USE THIS MANUAL
EXPLANATION OF MANUAL CONTENTS WEO000READS11002
DOIIC000R9001

GENERAL 00
SYMBOL DESCRIPTION
E Component Diagram
parts.
ing torque”

or type specified)
DOIIC000R9058
Sealant or adhesive
DOIIC000R9059

DOIIC000R9060

DOIIC000R9061

DOIIC000R9062
J
component parts.
Removal steps:
removal steps.

00 GENERAL
/ 10 HOW TO USE THIS MANUAL
SYMBOL DESCRIPTION
Disassembly steps:
disassembly steps.
Installation steps:
Reassembly steps:

or disassembly.
DOIIC000R9052

or reassembly
DOIIC000R9051

DOIIC000R9053

and reassembly are described.

GENERAL 00
ENGINE MODEL AND SERIAL NUMBER LOCATION / 11
ENGINE MODEL AND SERIAL

NUMBER LOCATION WEO000GINFO11001

cylinder block as shown in the following.

S4PH-CFE 1561 cm³ (95.25 cu.in)
the engine model number.
Engine serial number [Example]

DOINE11AR11151 AA0201 to YY9999
TIGHTENING TORQUE WEO000TTORQ11001
General tightening torque is as shown in the following table.

The specified part tightening torque is shown at the beginning of each group.
STANDARD PARTS TIGHTENING TORQUE
TIGHTENING TORQUE OF FLANGE BOLT
Classification
Flange bolt (Dia.) Thread size (Pitch x length) Specified torque
M5 0.6 mm (0.024 in) ± 0.1 kgm (1 Nm, 0.72
0.8 x 30 mm (0.031 x 1.18 in)
ft.lbs)
1.0 x 10 mm (0.039 x 0.39 in)
1.0 x 12 mm (0.039 x 0.47 in)
1.0 x 18 mm (0.039 x 0.71 in)
M6 1.0 x 20 mm (0.039 x 0.79 in) 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
1.0 x 25 mm (0.039 x 0.98 in)
1.0 x 35 mm (0.039 x 1.38 in)
1.0 x 50 mm (0.039 x 1.97 in)
1.25 x 16 mm (0.049 x 0.63 in)
1.25 x 25 mm (0.049 x 0.98 in)
2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
1.25 x 30 mm (0.049 x 1.18 in)
M8
1.25 x 40 mm (0.049 x 1.57 in)
1.25 x 70 mm (0.049 x 2.76 in) 1.2 kgm (12 Nm, 8.68 ft.lbs) ± 0.1 kgm (1
1.25 x 100 mm (0.049 x 3.94 in) Nm, 0.72 ft.lbs)
1.25 x 18 mm (0.049 x 0.71 in) SP 4.5-5.2 kgm (45-52 Nm, 32.55-37.61 ft.lbs)
1.25 x 25 mm (0.049 x 0.98 in) 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
M10 1.25 x 35 mm (0.049 x 1.38 in) 3.3-3.7 mm (0.13-0.15 in)
TIGHTENING TORQUE OF BOLT (SPECIAL)
Classification
Bolt (Dia.) Thread size (Pitch x length) Specified torque
M8 43 mm (1.69 in) 2.0 kgm (20 Nm, 14.47 ft.lbs) + 60°

00 GENERAL
Classification
Bolt (Dia.) Thread size (Pitch x length) Specified torque
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs) + 4.0 kgm (40 Nm, 28.93
ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs) + 5.0
M9 160 mm (6.3 in) ± 0.35 mm (0.014 in)
kgm (50 Nm, 36.16 ft.lbs) ± 0.2 kgm (2 Nm,
1.45 ft.lbs) + 60°(min), 64° (max) and
60°(min), 64° (max).
1.25 x 105 mm (0.049 x 4.13 in) 3.3-3.7 mm (0.13-0.15 in)
M10
4.91 kgm (49.1 Nm, 35.51 ft.lbs) ± 5.39 kgm
69 mm (2.72 in)
(53.9 Nm, 38.99 ft.lbs)
17.5 mm (0.69 in) 5.0 kgm (50 Nm, 36.16 ft.lbs) ± 0.2 kgm (2
26 mm (1.02 in) Nm, 1.45 ft.lbs) + 60°± 2°
M12
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 mm
30 mm (1.18 in)
(0.008 in) + 40 ± 2°
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2
M14 70 mm (2.76 in)
Nm, 1.45 ft.lbs) +120° ± 4°
TIGHTENING TORQUE OF FLANGE NUT (SPECIAL)
Classification
Flange nut (Dia.) Thread size (Pitch) Specified torque
M6 1.0 mm (0.039 in) 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
TIGHTENING TORQUE SCREW (SPECIAL)
Classification
Screw (Dia.) Thread size (Pitch) Specified torque
M6
TIGHTENING TORQUE STUD (SPECIAL)
Classification
Stud (Dia.) Thread size (Pitch x length) Specified torque
M6 1.0 x 50 mm (0.039 x 1.97 in) 0.5 kgm (5 Nm, 3.62 ft.lbs)
1.25 x 40 mm (0.049 x 1.57 in)
1.25 x 65 mm (0.049 x 2.56 in)
PRECAUTION BEFORE SERVICE WEO000BSERV11002
When the engine or transmission is disassembled and reassembled, pay attention to the following.

GENERAL 00
Removal and Disassembly For prevention of wrong installation or reas-

sembly and for ease of operation, put mating
mark (A) to the parts where no function is ad-
versely affected.
DOIIE00AR9001
Tightening Torque Tighten the part properly to specified torque.
DOIIE00AR9002
Replacement Part When oil seal, O-ring, packing and gasket have
been removed, be sure to replace them with
new parts.
However, rocker cover gasket may be reused if
it is not damaged.
DOIIE00AR9003
Oil and Grease Before reassembly, apply specified oil to the

rotating and sliding parts.
DOIIE00AR9004

00 GENERAL
Special Tool Be sure to use Special Tools when their use is

specified for the operation. Use of substitute
tools will resulting malfunction of the part or
damage it.
DOIIE00AR9005
Sealant Use specified brand of sealant.

Use of sealant other than specified sealant may
cause water or oil leaks.
DOIIE00AR9006
Rubber Part Do not stain timing belt and V-belt with oil or
water.
Therefore, do not cleaned the pulley and
sprocket with detergent.
DOIIE00AR9007
Genuine Part When the part is replace, be sure to use Proton

genuine part.
For selection of appropriate part, refer to the
Parts Catalog.
DOIIE00AR9008

ENGINE <S4P-CFE> 11A
Content /1
11A ENGINE <S4P-CFE>

SERVICE SPECIFICATIONS .......................................................... 11A/4
TORQUE SPECIFICATIONS ......................................................... 11A/5
NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING 11A/9
BOLTS ..................................................................................
SEALANTS ............................................................................ 11A/9
FORM-IN-PLACE GASKET(FIPG) ................................................... 11A/9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/10
Surface Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/10
From-in-Place Gasket Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/10
SPECIAL TOOLS ........................................................................ 11A/10
ALTERNATOR AND IGNITION SYSTEM ............................................ 11A/14

FEAD BELT ROUTE .................................................................. 11A/22
FUEL AND EMISSION CONTROL SYSTEM ........................................ 11A/25

INTAKE MANIFOLD ................................................................... 11A/28

EXHAUST MANIFOLD ................................................................ 11A/31

TIMING BELT ........................................................................... 11A/41

WATER PUMP AND WATER HOSE ................................................. 11A/51

CAMSHAFT AND TAPPET ........................................................... 11A/60

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/62
INSPECTION .......................................................................... 11A/76
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/76

/2 Content
CYLINDER HEAD AND VALVES ..................................................... 11A/77

INSPECTION .......................................................................... 11A/84
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/84
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/85
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/85
OIL PUMP AND OIL PAN ............................................................. 11A/88

INSPECTION .......................................................................... 11A/94
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/94
PISTON AND CONNECTING RODS ................................................. 11A/96

INSPECTION .......................................................................... 11A/100
PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/100
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC GAUGE METHOD) . . . . . . . . . . . . . . . . . . . . . . 11A/100
CRANKSHAFT AND CYLINDER BLOCK ............................................ 11A/109

INSPECTION .......................................................................... 11A/112
CRANKSHAFT OIL CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/112
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/112
BORING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A/113
REMOVAL AND INSTALLATION SERVICE POINTS ............................. 11A/120

Content /3
NOTE

/4 SPECIFICATIONS
SPECIFICATIONS WEO11ASPECS11008
Camshaft
Intake 27.05 mm (1.06 in) 26.55 mm (1.05 in)
Camshaft cam height
Exhaust 26.70 mm (1.05 in) 26.20 mm (1.03 in)
Camshaft journal diameter 27.94-27.96 mm (1.1-1.1 in) —
Cylinder head and valves
Flatness of cylinder head gasket surface 0.1 mm (0.004 in) or less —
Cylinder head gasket surface grinding limit (includ- 0.2 mm (0.008 in)
—
ing grinding of cylinder block gasket surface) (E)
Cylinder head overall height 134.7 mm (5.3 in)±0.25 mm
—
(0.01 in)
Cylinder head bolt nominal length 160 mm (6.3 in) 0.35 mm (0.014 in)
Intake 1.0 mm (0.039 in) 0.5 mm (0.02 in)
Valve margin
Intake 5.0 mm (0.2 in) —
Valve stem diameter
Exhaust 5.0 mm (0.2 in) —
Intake 0.02-0.047 mm (0.001-0.002 0.10 mm (0.004 in)
in)
Valve stem-to-guide clearance
Exhaust 0.03-0.057 mm (0.001-0.002 0.15 mm (0.006 in)
in)
Valve face angle 45°± 0.25° —
Intake 44.6 mm (1.76 in) —
Valve stem projection
Intake 101.50 mm (4 in) 101.00 mm (3.98 in)
(E)
Overall valve length
(E)
Intake 38.17 mm (1.5 in) 37.17 mm (1.46 in)
(E)
Valve spring free height
(E)
Valve spring load / installed height Intake 22.5 kg (225 N, 49.61
—
lbs)/30.27 mm (1.19 in)
Exhaust 22.5 kg (225 N, 49.61
—
lbs)/30.27 mm (1.19 in)
Valve spring squareness 1.59° 3° (E)
Valve seat contact width 0.9-1.3 mm (0.035-0.051 in) —
Valve guide internal diameter 5.0 mm (0.2 in) —
Valve guide projection Intake 12.0 mm (0.47 in) —
Oil pump and oil pan
Oil pump tip clearance 0.06-0.18 mm (0.002-0.007
—
in)

SPECIFICATIONS /5

Oil pump side clearance 0.03-0.10 mm (0.001-0.004
—
in)
Oil pump body clearance 0.04-0.10 mm (0.002-0.004 0.35 mm (0.014 in)
in)
Pistons and connecting rods
Piston outside diameter 75.975 mm (2.99 in) —
No. 1 ring 0.03-0.05 mm (0.001-0.002
—
in)
Piston ring side clearance
No. 2 ring 0.02-0.04 mm (0.001-0.002
—
in)
No. 1 ring 0.2-0.35 mm (0.008-0.014 in) 0.5 mm (0.02 in)
No. 2 ring 0.37-0.57 mm (0.015-0.022 0.5 mm (0.02 in)
Piston ring and gap clearance
in)
Oil ring 0.2-0.5 mm (0.008-0.02 in) 1.0 mm (0.039 in)
Piston pin O.D. 18.0 mm (0.71 in) —
Crankshaft pin oil clearance 0.02-0.044 mm (0.001-0.002 0.1 mm (0.004 in)
in)
Connecting rod big end side clearance 0.1-0.25 mm (0.004-0.01 in) 0.4 mm (0.016 in)
Crankshaft and cylinder block
Crankshaft end play 0.05-0.18 mm (0.002-0.007 0.25 mm (0.01 in)
in)
Crankshaft journal diameter 48.0 mm (1.89 in) —
Crankshaft pin diameter 46.0 mm (1.81 in) —
Crankshaft journal oil clearance 0.02-0.044 mm (0.001-0.002 0.1 mm (0.004 in)
in)
Cylinder block gasket surface flatness 0.03 mm (0.001 in) —
Cylinder block gasket surface grinding limit (includ- 0.2 mm (0.008 in)
—
ing grinding of cylinder head gasket surface)
Cylinder block overall height 255.85-256.15 mm (10.07-
—
10.08 in)
Cylinder block cylindricity 0.025 mm (0.001 in) —
Cylinder block I.D. (Bore) 76.0 mm (2.99 in) —
Piston to cylinder clearance 0.01-0.03 mm (0-0.001 in) —
TORQUE SPECIFICATIONS WEO11ASPECS11010
Items Value
Alternator, power steering pump, air-cond compressor and ignition system
Water pump pulley bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Alternator bolt (alternator side) 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Alternator pivot nut 3.3-3.7 kgm (33-37 Nm, 23.87-26.76 ft.lbs)
M8 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Fead belt tensioner bolt
M10 4.8-5.2 kgm (48-52 Nm, 34.72-37.61 ft.lbs)
Oil level gauge guide bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)

/6 SPECIFICATIONS
Items Value
TV damper bolt
ft.lbs) + 120°± 4°
1.75 kgm (17.5 Nm, 12.66 ft.lbs) ± 0.25 kgm (2.5
Spark plug
Nm, 1.81 ft.lbs)
Plug top coil bolt
ft.lbs)
Cam shaft sensor bolt
ft.lbs)
Oil control valve bolt 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Power steering pump bolt 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Air-cond compressor bolt 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Timing belt
Upper 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Timing belt cover bolt
Lower 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Timing belt tensioner bolt
1.45 ft.lbs)
Bolt M8 2.4 - 2.6 kgm (24 - 26 Nm, 17.36 - 18.81 ft.lbs)
Engine mounting bracket
Bolt M10 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)
(left)
Nut 3.3-3.7 kgm (33-37 Nm, 23.87-26.76 ft.lbs)
Back plate bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Intake 5.5-6.5 kgm (55-65 Nm, 39.78-47.01 ft.lbs)
Camshaft sprocket bolt 3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 Nm, 1.45
Exhaust
ft.lbs) + 40±2°
VVT bolt cap 3.0- 3.4 kgm (30- 34 Nm, 21.7- 24.59 ft.lbs)
Fuel system and emission system
Bracket harness fuel rail 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Throttle body bolt and bracket 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Fuel rail bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Water pump
Thermostat pipe assembly bolt 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Coolant temperature sensor 2.5-2.9 kgm (25-29 Nm, 18.08-20.98 ft.lbs)
Water pump bolt
ft.lbs)
M6 0.9- 1.1 kgm (9- 11 Nm, 6.51- 7.96 ft.lbs)
Bracket oil cooler
M10 3.3- 3.5 kgm (33- 35 Nm, 23.87- 25.32 ft.lbs)
Exhaust manifold and intake manifold
MAP sensor bolt
ft.lbs)
Intake manifold bolt and nut
0.72 ft.lbs)
Exhaust manifold heatshield bolt
1.45 ft.lbs)

SPECIFICATIONS /7
Items Value
Step Remark Value
(Nut no.1 to
no. 8 in as- 2.8 kgm (28 Nm, 20.25 ft.lbs) ± 0.2 kgm (2 Nm,
1
cending or- 1.45 ft.lbs)
Exhaust manifold nut der)
(Nut no.1 to
no. 8 in as- 2.8 kgm (28 Nm, 20.25 ft.lbs) ± 0.2 kgm (2 Nm,
2
cending or- 1.45 ft.lbs)
der)
Turbocharger heatshield bracket 0.9- 1.1 kgm (9- 11 Nm, 6.51- 7.96 ft.lbs)
Bolt
3.62 ft.lbs)
Brace support bracket
Nut
1.45 ft.lbs)
Turbocharger assy
3.62 ft.lbs)
Bracket bolt 0.6- 0.8 kgm (6- 8 Nm, 4.34- 5.79 ft.lbs)
Oil feed pipe
Banjo bolt 1.45- 1.75 kgm (14.5- 17.5 Nm, 10.49- 12.66 ft.lbs)
Bolt allen 0.9- 1.1 kgm (9- 11 Nm, 6.51- 7.96 ft.lbs)
Oil drain pipe
Banjo bolt 1.45- 1.75 kgm (14.5- 17.5 Nm, 10.49- 12.66 ft.lbs)
Pulse width modulation (PWM)
ft.lbs)
Electronic compressor relief valve (ECRV)
1.45 ft.lbs)
Lifting eye bolt 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Camshaft and Tappet lash adjuster
Cam cover bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Bearing cap bolt 0.9- 1.1 kgm (9- 11 Nm, 6.51- 7.96 ft.lbs)
Cylinder head and valves

/8 SPECIFICATIONS
Items Value
Step Remark Value
One bolt at
a time. Fol-
A low se-
1.45 ft.lbs)
quence no. 1
to no. 10
One bolt at
a time. Fol-
B low se-
ft.lbs)
quence no. 1
Cylinder head bolt to no. 10
One bolt at
a time. Fol-
C low se- 90°(min)
quence no. 1
to no. 10
One bolt at
a time. Fol-
D low se- 90°(min)
quence no. 1
to no. 10
Oil pump and oil pan
Oil pan bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Drain plug
3.62 ft.lbs)
Oil pan windage tray
ft.lbs)
Oil pan baffle bolt
ft.lbs)
Oil pick up pipe bolt
ft.lbs)
Front case bolt
ft.lbs)
Oil filter 1.2-1.6 kgm (12-16 Nm, 8.68-11.57 ft.lbs)
Relief valve
3.62 ft.lbs)
Oil pump backplate screw
1.45 ft.lbs)
Crank sensor 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Stud (Special) 0.8 - 1.2 kgm (8 - 12 Nm, 5.79 - 8.68 ft.lbs)
Pistons and connecting rods
2.2 kgm (22 Nm, 15.91 ft.lbs) ±0.2 kgm (2 Nm, 1.45
Connecting rod bolt
ft.lbs) + 90° ± 5°
Crankshaft and cylinder block
Direct damper flywheel bolt (DDF) 8.0- 9.0 kgm (80- 90 Nm, 57.86- 65.1 ft.lbs)
Rear plate bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
Rear oil seal case bolt 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)

SPECIFICATIONS /9
Items Value
Bearing cap bolt 4.91-5.39 kgm (49.1-53.9 Nm, 35.51-38.99 ft.lbs)
Oil pressure switch
ft.lbs)
Oil jet bolt 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.2 kgm (2 Nm, 1.45
ft.lbs)
Knock sensor 2.2-2.6 kgm (22-26 Nm, 15.91-18.81 ft.lbs)
Target wheel (Patch lock screw) 0.9- 1.1 kgm (9- 11 Nm, 6.51- 7.96 ft.lbs)
NEW TIGHTENING METHOD USING PLASTIC REGION TIGHTENING BOLTS WEO11ASPECS11011
Part of the engine use plastic region tightening bolts. The tightening procedure for these is different
from that of conventional bolts and is described in relevant parts of this manual. Note that plastic
region tightening bolts have fixed service limits. These are indicated in relevant parts of this manual
and must be strictly observed.
• Plastic region tightening bolts are used for the following applications:
1. Cylinder head bolts
• The tightening procedure is basically as follows:
After tightening a bolt to the specified torque, tighten the bolt with 2 times additional torque
angle.
The fist torque angle must within 60° (min) and 64° (max). It will be followed by second torque
angle with also within 60° (min) and 64° (max).
The exact tightening procedure differs depending on the bolt and is described in relevant parts
of this manual.
SEALANTS
Items Specified sealant Quantity
Oil pan
Threebond 1207F
Oil seal rear
Bushing knock
Threebond
Pin dowel
Plug tapper
TB 2403
Backplate cover bolt
Cylinder head (Cam bearing cap) TB 1110B
As required
Intake manifold bracket bolt TB 2440B
TB 1130
Oil pressure switch
3M ATD Part No.8660 or equivalent
Direct damper flywheel bolt
3M Nut Locking Part No.4171 or equivalent
Engine coolant temperature sensor
Piston – Connecting rod Yugen Kugyo Standards DS-711 or equival-
ent
FORM-IN-PLACE GASKET(FIPG) WEO11ASPECS11012
The engine has several areas where the form-in place gasket (FIPG) is in use. To ensure that the gasket
fully servesits purpose, it is necessary to observe some precautions when applying the gasket. Bead
size, continuity and location are of paramount importance. Too thin a bead could cause leaks. Too
thick a bead, on the other hand, could be squeezed out of location, causing blocking or narrowing
of the fluid feed line. To eliminate the possibility of leaks from a joint, therefore , it is absolutely ne-
cessary to apply the gasket evenly without a break, while observing the correct bead size.

/ 10 SPECIAL TOOLS
The FIPG used in the engine is a room temperature vulcanization (RTV) type and is supplied in a
100–gram tube (Part No. MD970389, MD997110 or PC111001). Since the RTV hardens as it reacts with
the moisture in the atmospheric air, it is normally used in the metallic flange areas. The FIPG, Part No.
MD970389, can be used for sealing both engine oil and coolant, while Part No. MD970389, MD997110
or PC111001 can only be used for engine oil sealing.
Disassembly
The parts assembled with the FIPG can be easily disassembled without use of a special method. In
some cases, however, the sealant between the joined surfaces may have to be broken by lightly
striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in
between the joined surfaces. In this case, however, care must be taken to prevent damage to the
joined surfaces. For removal of the oil pan, the special tool “Oil Pan Remover” (MD998727) is available.
Be sure to use the special tool to remove the oil pan. <Except aluminium die-cast oil pans>
Surface Preparation
Thoroughly remove all substances deposited on the gasket application surfaces, using a gasket scraper
or wire brush. Check to ensure that the surfaces to which the FIPG is to be applied is flat. make sure
that there are no oils, greases and foreign substances deposited on the application surfaces. Do not
forget to remove the old sealant remained in the bolt holes.
From-in-Place Gasket Application
When assembling parts with the FIPG, you must observe some precautions, but the procedures is very
simple as in the case of a conventional precut gasket.
Applied FIPG bead should be of the specified size and without breaks. also be sure to encircle the bolt
hole circumference with a completely continuous bead. The FIPG can be wiped away unless it is
hardened. While the FIPG is still moist (in less than 15 minutes), mount the parts in position. When
the parts are mounted, make sure that the gasket is applied to the required area only. In addition,
do not apply any oil or water to the sealing locations or start the engine until a sufficient amount of
time (about one hour) has passed after installation is completed.
The FIPG application procedure may vary on different areas. Observe the procedure described in the
text when applying the FIPG.
SPECIAL TOOLS WEO11ASTOOL11004

EZT 0011 Crankshaft rear oil Installation of crankshaft
seal installer rear oil seal
DOIHC11AR04045

DOIIE11AR9004

SPECIAL TOOLS / 11

MD998304 Crankshaft front oil Installation of crankshaft
seal installer front oil seal
DOIIE11AR9005
MD998305 Crankshaft front oil Guide for installation of

seal guide crankshaft front oil seal
DOIIE11AR9006
MB991653 Cylinder head bolt Removal and installation of

wrench (10) cylinder head bolt
DOIIE11AR9016
MB991396 Oil filter wrench Removal and installation of

engine oil filter (When using
the oil filter of MD135737)
DOIIC012R9001
MD998770 Oxygen (Lambda) Removal and installation of

sensor wrench Oxygen (Lambda) sensor and
coolant temperature sensor
DOIIC015R9001
Mot. 59104 Angle gauge To get accurate angle during

and TV damper bolt
DOIGE11AR03136
EZT 0001 Valve collet installer To insert valve collet into

valve groove accurately
DOIGE11AR03132

/ 12 SPECIAL TOOLS

EZT 0002 Valve collet remover To remove valve collet
DOIGE11AR03162
EZT 0003 TV damper stopper To lock TV damper from

turning
DOIGE11AR03105
EZT 0005 Valve stem seal plier To install and remove valve
stem seal and spring seat
from valve
DOIGE11AR03104

staller seal
DOIGE11AR03155

DOIGE11AR03146
EZT 0008 Con rod jig To guide connecting rod and

connecting rod bearing dur-
ing installation
DOIGE11AR03160
To prevent camshaft sprock-

Camshaft Sprocket
EZT 0004 et from turning during in-
Stopper
stalling timing belt
DOIGE11AR03134

SPECIAL TOOLS / 13
EZT 0044 Flywheel Stopper To lock flywheel
DOIME11AR11051
To support valve during re-

Cylinder Head Valve
EZT 0046 moving and installing valve
Jig
collet
DOIME11AR11053
Holding camshaft sprocket

MB990767 End Yoke holder when loosening or tighten-
ing bolt (used MD998715)
DOIIE11AR9002
Holding camshaft sprocket

MD998715 Pin (2–off) when loosening or tighten-
ing bolt (used MD990767)
DOIIE11AR9008

/ 14 ALTERNATOR AND IGNITION SYSTEM
ALTERNATOR AND IGNITION SYSTEM WEO11ASASSY10002
DOINE11AR10001

ALTERNATOR AND IGNITION SYSTEM / 15

● Cam shaft sensor (Refer Workshop Manual Chassis GROUP 13A, Fuel- On Vehicle Service- Cam shaft
sensor)
● Alternator (Refer Workshop Manual Chassis GROUP 016- Alternator Disassembly And Reassembly
Service Point)
● Spark plug (Refer Workshop Manual Chassis GROUP 016, Ignition System- Inspection)
● Plug top coil (Refer Workshop Manual Chassis GROUP 016, Ignition System- Inspection)
● Oil control valve (Refer Workshop Manual Chassis GROUP 13A, Fuel- On Vehicle Service- Oil Control
Valve Installation Service Point)
: Non-reusable parts
Removal steps :
1. Plug top coil
2. Spark plug
3. Cam shaft sensor
4. Oil control valve
5. Fead belt
7. Alternator
9. Power steering pump
10. Air-cond compressor
11. TV damper pulley
12. Oil level gauge
T4 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T5 : 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T6 : 3.3 - 3.7 kgm (33 - 37 Nm, 23.87 - 26.76 ft.lbs)
T8 : 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)

REMOVAL SERVICE POINTS WEO11ASPROC10001
WATER PUMP PULLEY REMOVAL

1. Before removing fead belt, loosen 3 pieces
water pump pulley bolts.
Symbol Description
A Ratchet
B Water pump pulley bolts
DOINE11AR11041
TV DAMPER BOLT AND TV DAMPER

REMOVAL
1. Use the special tool (EZT 0003) to hold the
TV damper in order to loose TV damper bolt.
Symbol Description
A TV damper bolt
B TV damper pulley
C Dowel
D Crankshaft
E Sprocket crankshaft
DOIGE11AR03156


TV DAMPER BOLT AND TV DAMPER
INSTALLATION
1. Hold TV damper by using special tool (EZT
0003).
Symbol Description
A TV damper bolt
B TV damper pulley
C Dowel
D Crankshaft
E Sprocket crankshaft
2. Tighten TV damper bolt to the specified
torque.
Steps Specified torque

3.0 kgm (30 Nm, 21.7 ft.lbs) ±
1
0.2 kgm (2 Nm, 1.45 ft.lbs)
DOINE11AR11085
3. By using the special tool (MOT 591-04),

tighten the TV damper bolt by turning at
120° ± 4°.
DOINE11AR11156


1. Locate water pump pulley on the front case.
The “FRONT” marking on the water pump
pulley is facing towards the mechanic.
NOTE :
Make sure the ‘FRONT’ making must be the
same direction with water pump ‘DOT’ mark.
2. Install and tighten the bolts to the specified
torque.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Symbol Description
A Water pump pulley
B Water pump
C Bolt
DOIGE11AR03003
CAM POSITION SENSOR INSTALLATION

1. Tighten the cam position sensor bolt to the
specified torque.
Specified torque :
0.72 ft.lbs)
Symbol Description
A Cam position sensor
B Bolt
DOINE11AR11042

1. Install alternator lower bolt and nut to the
front cover assy. Pre-tighten 2 to 3 times the
alternator lower nut and lift up the alternat-
or to the correct position.
Symbol Description
A Alternator lower bolt
B Alternator lower nut
DOINE11AR11043
2. Tighten the alternator upper bolt to the

specified torque.
Specified torque :
2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
Symbol Description
C Alternator upper bolt
DOINE11AR11157
3. Tighten alternator lower nut to the specified

torque.
Specified torque :
3.3 - 3.7 kgm (33 - 37 Nm, 23.87 - 26.76 ft.lbs)
Symbol Description
B Alternator lower nut
DOINE11AR11044

SPARK PLUG INSTALLATION

1. Install spark plug to cylinder head assy to the
specified torque.
Specified torque :
1.75 kgm (17.5 Nm, 12.66 ft.lbs) ± 0.25 kgm
(2.5 Nm, 1.81 ft.lbs)
Spark plug gap :

0.6 - 0.7 mm (0.024 - 0.028 in)
Symbol Description
A Spark plug
DOINE11AR11046
PLUG TOP COIL INSTALLATION

1. Ensure the plug top coil rubber shoulder
should seat properly on cam cover lip.
2. Tighten plug top coil to the specified torque.
Specified torque :
0.72 ft.lbs)
Symbol Description
A Section view
B Plug top coil rubber shoulder
DOINE11AR11045

OIL CONTROL VALVE INSTALLATION

1. Before installing the oil control valve to the
cylinder head, make sure the filter element
and o-ring are fixed properly in the oil con-
trol valve.
Insert the oil control valve into the cylinder
head and tighten the bolt to the specified
torque.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
CAUTION :
Ensure the filter element installed correctly
in order to prevent wrong installation and
cause engine operation failure.
Symbol Description
A Oil control valve
B O-ring
C Filter element
DOINE11AR11047

FEAD BELT ROUTE WEO11ASASSY10005
DOINE11AR11048
Symbol Description
1 Fead belt tensioner
2 TV damper
3 Air-cond compressor pulley
5 Water pump upper pulley
6 Alternator pulley
7 Water pump lower pulley
T5 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T8 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)


FEAD BELT REMOVAL
arm.
2. Push the ratchet towards engine intake side
or.
3. Loosen the fead belt tensioner half way.
DOINE11AR11049

1. Locate fead belt on top of power steering
pulley and tv damper.
DOIGE11AR03009
2. Install fead belt tensioner assy to the front

case as shown in the illustration. Tighten
fead belt tensioner bolt to the specified
torque.
2.2-2.6 kgm (22-26 Nm, 15.91-

T5
18.81 ft.lbs)
4.8-5.2 kgm (48-52 Nm, 34.72-
T8
37.61 ft.lbs)
DOINE11AR11072

roller nicely.
NOTE :
fead belt is facing outward.
Symbol Description
A Fead belt
DOINE11AR11158


arm.
Symbol Description
A Ratchet
DOIGC11AR03029

clockwise in the sequence of 1 → 2 → 3 → 4
Symbol Description
A Ratchet
1 TV damper
2 Air-cond compressor pulley
4 Water pump pulley
DOIGC11AR03030
6. While ensuring no slack, push the ratchet

(A) toward engine to replace the fead belt
and then complete the belt installation
around alternator pulley and water pump
pulley.
Symbol Description
A Ratchet
5 Alternator pulley
6 Water pump pulley
DOINE11AR11050
adjust to ensure fead belt in correct and
good position.

FUEL AND EMISSION CONTROL SYSTEM / 25
FUEL AND EMISSION CONTROL SYSTEM WEO11ASASSY10009
DOINE11AR11125

• Injector (Refer Workshop Manual Chassis GROUP 13A- Injector)
— Lubricate all o-rings injector with engine oil during reassembly

Removal steps :
1. Bracket harness fuel rail 8. Throttle body seal
2. Fuel rail assy
3. Injector clip
4. O-ring
5. Injector
6. Bracket harness throttle body
7. Throttle body
T1 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)

/ 26 FUEL AND EMISSION CONTROL SYSTEM
INJECTORS REMOVAL
Symbol Description
A Injector clip
B Fuel rail
C Injector

INJECTORS INSTALLATION
1. Fit a new o-ring, on the injector.
Symbol Description
A O-ring
2. Coat the o-ring with oil.
CAUTION :
(1) Be sure not to let oil get into the fuel
rail.
DOIME13BR07004 (2) Beware not to insert injector slantingly.

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

FUEL AND EMISSION CONTROL SYSTEM / 27

Symbol Description
D Injector clip
E Injector slot
DOIME13BR07006
THROTTLE BODY INSTALLATION

1. Install the throttle body gasket into the in-
take manifold groove.
2. Fix the throttle body to the intake manifold.
3. Tighten the 4 pcs throttle body bolt to the
specified torque.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Symbol Description
A Throttle body gasket
DOINE11AR11040
B Intake manifold groove
C Throttle body
D Throttle body bolts

INTAKE MANIFOLD WEO11ASASSY11019
DOINE11AR11128

• Intake manifold (Refer Workshop Manual Chassis GROUP 015- Disassembly And Reassembly Service
Point)
Removal steps :
1. Map sensor 6. Fuel vapor hose 2
2. Hose clamp 7. Breather hose 1 (Part load)
3. Purge solenoid valve 8. High tension clamp
4. Fuel vapor hose 1 9. Breather hose 2
5. No-return valve 10. Intake manifold


WEO11ASPROC11029
MAP SENSOR INSTALLATION

Install MAP sensor to intake manifold and tight-
en to the specified torque.
0.72 ft.lbs)
Symbol Description
DOINE11AR11119
A MAP sensor
B Intake manifold

Before installing the no-return valve, ensure the
arrow direction is facing to the electronic throttle
body.
Symbol Description
A No-return valve
B Arrow
DOIME11AR07014
INTAKE MANIFOLD INSTALLATION

1. Install intake manifold gasket into the intake
manifold groove as shown in the illustration.
Symbol Description
A Intake manifold gasket
B Intake manifold
C Intake manifold groove
DOINE11AR11121

2. Install intake manifold to the cylinder head

and then tighten bolt flange and nut to the
specified torque.
Tighten the bolt flange according to the se-
quence numbers as shown in the illustration.
Specified torque (C and E) :
2.4 kgm (24 Nm, 17.36 ft.lbs) ± 0.1 kgm (1
Nm, 0.72 ft.lbs)
Symbol Description
C Bolts
DOINE11AR11120
D Intake manifold
E Nuts
3. Install oil cooler bracket to the intake mani-
fold and then tighten the bracket bolt to the
following specified torque.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Symbol Description
A Bracket bolts
B Intake manifold
DOINE11AR11122

EXHAUST MANIFOLD WEO11ASASSY11021
DOINE11AR11172
Pre-removal and post-installation.

• Turbocharger assy (Refer Workshop Manual Chassis GROUP 015 - Turbocharger Assy Disassembly
And Reassembly Service Point)
• Recirculation pump (Refer Workshop Manual Chassis GROUP 014 - Recirculation Pump Removal
And Installation)
Removal steps :
1. Oil feed pipe 10. Exhaust manifold gasket
2. Recirculation pump 11. Exhaust manifold
3. Oil drain pipe

4. Oil drain pipe gasket
5. Turbocharger assy
6. Turbocharger gasket
7. Turbocharger heatshield
bracket
8. Exhaust manifold heat-
shield
9. Brace support bracket

T1 :0.6 - 0.8 kgm (6 - 8 Nm, 4.34 - 5.79 ft.lbs)

T2 :0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T3 :1.45 - 1.75 kgm (14.5 - 17.5 Nm, 10.49 - 12.66 ft.lbs)
T4 :2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T5 :2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.5 kgm (5 Nm, 3.62 ft.lbs)
T7 : Tightening torque procedures for exhaust manifold
Steps Torque Bolt numbers
2.8 kgm (28 Nm, 20.25 ft.lbs) ±
A
0.2 kgm (2 Nm, 1.45 ft.lbs) Bolt no. 1 to no.8
2.8 kgm (28 Nm, 20.25 ft.lbs) ± In ascending order
B
0.2 kgm (2 Nm, 1.45 ft.lbs)

RECIRCULATION PUMP REMOVAL

1. Remove recirculation pump hose upper
clamp from turbocharger coolant feed pipe.
2. Then, remove recirculation pump hose lower
clamp from cylinder block.
Symbol Description
A Recirculation pump
Recirculation pump hose upper
B
DOINE11AR11079
clamp
C Coolant feed pipe
D Turbocharger assy
Recirculation pump hose lower
E
clamp
F Cylinder block
OIL FEED PIPE REMOVAL

1. Remove oil feed pipe banjo upper bolt.
Symbol Description
A Banjo upper bolt
DOINE11AR11078
2. Remove oil feed pipe banjo side bolt and oil

feed pipe bracket bolt.
Symbol Description
B Oil feed pipe banjo side bolt
C Oil feed pipe bracket bolt
DOINE11AR11123

OIL DRAIN PIPE REMOVAL

1. Remove oil drain pipe screw and gasket
lower side as shown in the illustration.
Symbol Description
A Oil drain pipe screw
B Gasket lower side
C Allen key
DOINE11AR10004
TURBOCHARGER ASSY REMOVAL

1. Remove 3 pcs nut turbocharger assy as shown
Symbol Description
A Turbocharger assy
B Exhaust manifold
C Cylinder block
D Turbocharger assy nut
DOINE11AR11081

EXHAUST MANIFOLD HEATSHIELD

REMOVAL
1. Remove 4 pcs bolt exhaust manifold heat-
shield.
Symbol Description
A Exhaust manifold
B Exhaust manifold heatshield
C Bolt
DOINE11AR11138
BRACE SUPPORT BRACKET REMOVAL

1. Remove bolt and nut brace support bracket
Symbol Description
A Exhaust manifold
B Brace support bracket
C Bolt
D Nut
DOINE11AR11139
EXHAUST MANIFOLD REMOVAL

1. Remove 8 pcs nut exhaust manifold.
Symbol Description
A Exhaust manifold
DOINE11AR11140


TURBOCHARGER ASSY INSTALLATION
1. Install turbocharger gasket as shown in the
illustration.
Symbol Description
A Turbocharger gasket
Turbocharger gasket part
B
number
C Turbocharger assy
D Exhaust manifold
DOINE11AR11137
2. Install turbocharger assy to exhaust manifold

and tighten the nut to the specified torque.
Specified torque (A) :
2.8 kgm (28 Nm, 20.25 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
Symbol Description
A Exhaust manifold nut
B Exhaust manifold
C Turbocharger assy
DOINE11AR10007

OIL DRAIN PIPE INSTALLATION

1. Insert gasket slot into pipe oil drain as shown
2. Install oil drain pipe allen bolt to cylinder
block and tighten to the specified torque.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Symbol Description
A Oil drain pipe allen bolt
B Oil drain pipe gasket
C Oil drain pipe
DOINE11AR10004
OIL FEED PIPE INSTALLATION

1. Pre-tighten banjo bolt with cooper washer
to the turbocharger as shown in the view C
and view D.
2. Then, tighten bolt banjo with cooper washer
1.45 - 1.75 kgm (14.5 - 17.5 Nm, 10.49 - 12.66
ft.lbs)
3. Tighten the oil feed pipe bracket to the spe-

cified torque.
0.6 - 0.8 kgm (6 - 8 Nm, 4.34 - 5.79 ft.lbs)
Symbol Description
A Cooper washer
B Banjo bolt
E Oil feed pipe bracket
DOINE11AR10010

RECIRCULATION PUMP INSTALLATION

1. Sub-assy recirculation pump is installed onto
the assy-engine before assy-transmission in-
stalled.
2. Install recirculation pump hose to turbo into
coolant feed pipe on turbocharger and se-
cure with clip A.
3. Install recirculation pump hose into connect-
or on cylinder block and secure with clip B.
4. Install sub-assy recirculation pump onto the
assy-transmission as show and secure with
bolt to specified torque.
Specified torque :
2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
Symbol Description
A Clip A
B Clip B
C Recirculation pump
D Coolant feed pipe
NOTE :
1) Ensure the recirculation pump hose to turbo,
recirculation pump hose to block are free from
DOINE11AR11124 damage, foreign particles and oil.
2) Ensure install with fixing holes and white mark
is towards specified direction.
3) Use the specified clips.

1. Install exhaust manifold gasket to cylinder
head studs as shown in the illustration.
NOTE :
Ensure the ‘UP’ marking at exhaust manifold
is facing to the exhaust manifold side.
Symbol Description
A Exhaust manifold gasket
B Exhaust manifold
DOINE11AR11141 C ‘UP’ marking

2. Install exhaust manifold (B) to cylinder head

studs.
According to the tightening sequence as
shown in the illustration, tighten the nuts to
Step Torque Sequence proced-
ure
2.8 kgm (28
Nm, 20.25
1 ft.lbs) ± 0.2
kgm (2 Nm, Bolt no. 1 to no.
1.45 ft.lbs) 8
2.8 kgm (28 (In ascending or-
Nm, 20.25 der)
2 ft.lbs) ± 0.2
kgm (2 Nm,
1.45 ft.lbs)
DOINE11AR11142
EXHAUST MANIFOLD HEATSHIELD

INSTALLATION
1. Install exhaust manifold heatshield onto cyl-
inder head and then tighten to the specified
torque.
2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
Symbol Description
A Exhaust manifold heatshield
DOINE11AR11143

BRACE SUPPORT BRACKET INSTALLATION

1. Install brace support bracket at cylinder block
and exhaust manifold sides.
2. Secure support brace by finger, tightening
bolt and nut .
3. Tighten the bolt and nut to the specified
tightening torque.
Symbol Description
A Bolt
B Nut
C Brace support bracket
Specified torque nut ( T1 ) :
2.8 kgm (28 Nm, 20.25 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
Specified torque bolt ( T2 ) :

2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.5 kgm (5
Nm, 3.62 ft.lbs)
DOINE11AR11083

TIMING BELT / 41
TIMING BELT WEO11ASASSY10006
DOINE11AR11114
Removal steps :
1. Timing belt upper cover 6. Crankshaft sprocket
2. Timing belt lower cover 7. VVT bolt cap
3. Engine mounting bracket 8. Camshaft exhaust sprocket
4. Timing belt tensioner 9. Camshaft VVT sprocket
5. Timing belt 10. Backplate cover
T1 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T3 : 3.3 - 3.7 kgm (33 - 37 Nm, 23.87 - 26.76 ft.lbs)
T4 : 2.4 - 2.6 kgm (24 - 26 Nm, 17.36 - 18.81 ft.lbs)
T5 : 4.8 - 5.2 kgm (48 - 52 Nm, 34.72 - 37.61 ft.lbs)
T6 : 3.0 - 3.4 kgm (30 - 34 Nm, 21.7 - 24.59 ft.lbs)

/ 42 TIMING BELT
TIMING BELT AND TIMING BELT TENSIONER

REMOVAL
1. Remove the timing belt upper cover stud bolt
from cylinder head by using standard tool.
Symbol Description
Timing belt upper cover stud
A
bolt
DOINE11AR11159
2. Align camshaft sprocket timing marks “A”

with cam cover marks “B”. Ensure that
crankshaft is safe position (90° ATDC) for
cylinder no. 1
Symbol Description
A Camshaft sprocket marks
B Cam cover marks
DOINE11AR11020
3. By using the special tool (EZT 0007), align the

crankshaft sprocket to dowel pin to the front
case marking at one o’clock position.
Symbol Description
C Crankshaft sprocket dowel pin
E TV damper bolt
DOIGE11AR03141
4. Insert the special tool in between two cam-

shaft sprockets in order to ensure the cam-
shaft sprockets “STOP” from turning.
Symbol Description
DOINE11AR11155

TIMING BELT / 43
5. If reused timing belt, draw an arrow on the

belt to indicate the rotation direction before
removing the belt. This will ensure the timing
belt is fitted correctly when it reused.
DOINE11AR11023
6. Loosen the timing belt tensioner bolt by us-

ing ratchet. Then, remove the timing belt
tensioner and timing belt together.
CAUTION :
To remove the tensioner bolt, make sure use
the correct socket is used in order to prevent
tensioner head bolt from damage and wear.
Symbol Description
B Ratchet
DOINE11AR11021 C Timing belt tensioner
CAMSHAFT EXHAUST SPROCKET BOLT

REMOVAL
1. By using special tool as shown in the illustra-
tion, lock the camshaft exhaust sprocket.
2. Loosen the camshaft exhaust bolt.
Symbol Description
A Ring spanner
B Special tool (MB990767)
C Special tool (MD998715)
DOINE11AR11184

/ 44 TIMING BELT

WEO11ASPROC10005
CAMSHAFT EXHAUST SPROCKET BOLT

INSTALLATION
1. Locate the camshaft exhaust sprocket on the
dowel pin camshaft exhaust as shown in the
illustration.
Symbol Description
A Pin dowel camshaft exhaust
DOINE11AR11104
2. By using the special tool, lock the camshaft

exhaust sprocket and tighten the camshaft
exhaust sprocket bolt to the specified torque
Specified torque :
1.45 ft.lbs)
Symbol Description
DOINE11AR11185 C Torque wrench
TIMING BELT AND TIMING BELT TENSIONER

INSTALLATION
1. Align camshaft sprocket timing marks with
cam cover marks and lock the sprocket by
using special tool as shown in illustration.
NOTE :
Symbol Description
A Cam cover marks
DOINE11AR11027

TIMING BELT / 45
Symbol Description
B Camshaft sprocket timing
marks
2. By using the special tool (EZT 0007) align the
crankshaft sprocket dowel pin to the front
case marking at one o’clock position.
Symbol Description
C Crankshaft sprocket dowel pin
E TV damper bolt
DOIGE11AR03024
3. Fit timing belt tensioner bearing by putting

the timing belt tensioner foot into the core
plug and ensure the allen key hole is posi-
tioned opposite to the foot as shown in illus-
tration.
Symbol Description
A Timing belt tensioner
B Timing belt tensioner foot
C Core plug
D Allen key hole
DOINE11AR11058 E Timing belt tensioner bolt
4. Pre-tighten the timing belt tensioner bolt by
hand.
DOIGE11AR03177

/ 46 TIMING BELT

shaft sprocket and camshaft sprockets. Then,
fit timing belt around timing belt tensioner
pulley and push fully the timing belt onto all
sprockets and pulley as shown in the illustra-
tion.
Caution:
Ensure no slack along span 1 [S1] and span
2 [S2] area.
DOINE11AR11051
7. Turn the timing belt tensioner clockwise until

timing belt tensioner pointer indicator is ex-
actly over the right hand side edge of indic-
ator notch (refer view A). Then, tighten bolt
tensioner whilst holding the allen key in
place.
Specified torque :
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
Symbol Description
A Timing belt tensioner
Timing belt tensioner
B
pointer indicator
C Indicator notch
D Allen key
E Ratchet
DOINE11AR11053

TIMING BELT / 47

damper bolt, rotate the engine twice (720º
crankshaft rotation). Ensure the crankshaft
dowel pin marking is align back to the front
case.
CAUTION :
Remove special tool (EZT 0004) from it posi-
tion before rotating the crankshaft sprocket.
Symbol Description
A TV damper bolt
Crankshaft sprocket
DOINE11AR11161 B
dowel pin
C Front case marking
position at the centre of the indicator notch,
the timing belt is in the required timing belt
tension specification as shown in the illustra-
tion.
DOINE11AR11052

/ 48 TIMING BELT
10. If the indicator does not stops within the

while loosening bolt tensioner with torque
on (view D).
Symbol Description
A Allen key
B Torque wrench
DOINE11AR11055
11. Rotate tensioner bearing clockwise until the

pointer is positioned in the centre of the
12. Retighten bolt tensioner whilst holding the
allen key in place.
Specified torque :
2.5 kgm (25 Nm, 18.08 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
Symbol Description
A Allen key
B Torque wrench
DOINE11AR11056

TIMING BELT / 49

damper bolt, rotate the engine twice (720º
crankshaft rotation). Ensure the crankshaft
dowel pin marking is align back to the front
case.
CAUTION :
Remove special tool (EZT 0004) from it posi-
tion before rotating the crankshaft sprocket.
Symbol Description
A TV damper bolt
B Crankshaft sprocket dowel pin
C Front case marking
DOINE11AR11057

sition at the centre of the indicator notch,
the timing belt is in the required timing belt
tension specification. If the indicator still
does not stops in the middle of the indicator
notch, repeat procedures no.1 until no.14.
DOINE11AR11052

/ 50 TIMING BELT

again the special tool in between of two
camshaft sprockets in order to make sure the
camshaft sprockets “STOP” from turning.
Symbol Description
DOINE11AR11155
17. Then, turn TV damper bolt anti-clockwise to

loose TV damper bolt and special tool.
Symbol Description
A TV damper bolt
B Special tool (EZT 0007)
DOINE11AR11162
TIMING BELT LOWER COVER AND UPPER

COVER INSTALLATION
bolt flange.
0.9 -1.1 kgm (9 -11 Nm, 6.51 -7.96 ft.lbs)

cylinder head front side and tigthen the bolt
flange.
DOINE11AR11032 Specified torque (T1) :
0.9 -1.1 kgm (9 -11 Nm, 6.51 -7.96 ft.lbs)

WATER PUMP AND WATER HOSE / 51
WATER PUMP AND WATER HOSE WEO11ASASSY10010
DOINE11AR11094

• Oil cooler (Refer Workshop Manual Chassis GROUP 014- Oil Cooler Disassembly And Reassembly
Service Point)
— Sealant
Removal steps :
1. Retainer clip 9. Water pump seal
2. Washer 10. Water pump
11. Oil cooler
3. Thermostat
4. Thermostat seal
5. Thermostat pipe assy
6. Return hose
7. Seal

/ 52 WATER PUMP AND WATER HOSE
T1 : 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)

T3 : 2.5 - 2.9 kgm (25 - 29 Nm, 18.08 - 20.98 ft.lbs)
T4 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T5 : 3.3 - 3.5 kgm (33 - 35 Nm, 23.87 - 25.32 ft.lbs)


REMOVAL
Use special tool to remove the engine coolant
temperature sensor.
DOIGE11AR03123
THERMOSTAT REMOVAL
1. Use circlip plier to remove retainer clip.
2. Then,use a screw driver to pry out the wash-
er.
3. The thermostat can be removed by using
plier.
Symbol Description
A Circlip plier
B Retainer clip
C Thermostat pipe
DOINE11AR11009
D Washer
E Thermostat

OIL COOLER REMOVAL

1. Remove oil cooler bracket bolts (E).
2. Release all oil cooler hose clamps as shown
Symbol Description
A Oil feed hose
B Oil return hose
C Feed coolant hose
D Return coolant hose
E Oil cooler bracket bolt
F Oil cooler
DOINE11AR11012
THERMOSTAT PIPE ASSY REMOVAL

1. Release coolant return hose clamp from cyl-
inder head.
2. Remove bolts bracket thermostat pipe.
Symbol Description
Bolt thermostat pipe at cylinder
A
block
Coolant return hose from cylinder
B
block
DOINE11AR11013

WEO11ASPROC10024
THERMOSTAT INSTALLATION
1. Fit the thermostat seal to the thermostat se-
curely.
2. Fit the thermostat into thermostat pipe assy
NOTE :
Ensure the bleed hole is at the top position
.25 ° ± 5 °.
DOINE11AR11014

Symbol Description
A Thermostat pipe assy
B Thermostat seal
C Thermostat
D Washer
E Retainer clip
3. Fit securely the washer and insert retainer
clip using circlip plier into thermostat pipe
assy securely.
NOTE :
(1) Make sure the retainer clip holes is in
lower position.
(2) Ensure the thermostat washer and retain-
er clip are properly inserted in the groove
(F).
DOINE11AR11015

THERMOSTAT PIPE ASSY INSTALLATION

thermostat seal at the thermostat pipe as-
sembly. Press the water pump case assembly
while twist it left and right . Careful to not
damage the thermostat seal.
for any damage. Then, re-insert the new
procedure no.1.
3. Tighten the thermostat pipe bolt to the spe-
cified torque.
Specified torque :
2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
Symbol Description
A Thermostat seal
B Thermostat pipe
C Return hose
D Thermostat pipe assy bolt
E Front case
DOINE11AR11016
OIL COOLER INSTALLATION

NOTE :
Use soap water for easy assembly of oil cooler
hoses.
1. Install the oil return hose to the cylinder
block. Fix the hose clamp according to the
hose clamp marking as shown in the illustra-
tion.
2. Install the oil feed hose to the front case. Fix
the hose clamp according to the hose clamp
marking as shown in the illustration.
DOINE11AR11069
CAUTION :
(Procedure no.2 and no.3)
The hose clamp shall be securely positioned
after the bulge area.
Symbol Description
A Oil return hose
B Oil feed hose
C ‘Norma’ hose clamp
D Oil cooler
E Cylinder block
F Front case

3. Install the coolant feed hose to the front

case.
CAUTION :
Fix the hose clamp according to the hose
clamp marking as shown in the illustration.
Symbol Description
A Coolant feed hose
B Hose clamp
C Oil cooler
D Hose clamp marking
DOINE11AR11070
4. Install the coolant return hose to the thermo-

stat pipe.
CAUTION :
Fix the hose clamp according to the hose
clamp marking as shown in the illustration.
Symbol Description
A Coolant return hose
B Hose clamp
C Oil cooler
D Thermostat pipe
E Hose clamp marking
DOINE11AR11071

5. Push clamp (F) on hose A and B over the

bulge and tighten as shown in the illustra-
tion.
NOTE :
Ensure that the half circle lies on the swaged
section of the stub pipe.
Symbol Description
A Oil return hose
B Oil feed hose
C “Norma” clamp
D Oil cooler
E Hose clamp marking
DOINE11AR11090
6. Pre-tighten all 4 pcs oil cooler bracket bolts

DOINE11AR11091
7. Tighten all 4 pcs oil cooler bracket bolts to

NOTE :
Ensure there is no gap between bracket ,oil
cooler and inlet manifold
Specified torque (for bolt A) :
3.3 - 3.5 kgm (33 - 35 Nm, 23.87 - 25.32 ft.lbs)
Specified torque (for bolt B) :

0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
DOINE11AR11092

Symbol Description
Oil cooler lower bracket
A
bolt
Oil cooler upper bracket
B
bolt
C Oil cooler bracket

INSTALLATION
1. If reused the engine coolant temperature
sensor, apply the specified sealant to the
thread.
Specified sealant :
DOIGE11AR03039
2. Use special tool (MD998770) to tighten the

engine coolant temperature sensor to the
specified torque.
Specified torque :
2.5 - 2.9 kgm (25 - 29 Nm, 18.08 - 20.98 ft.lbs)
DOIGE11AR03123

CAMSHAFT AND TAPPET WEO11ASASSY10013
DOINE11AR11093

— Sealant
— Lubricate all internal parts with engine oil during reassembly
Removal steps :
1. Breather hose (Full load)
2. Breather hose (Part load)
3. Oil filler cap
4. Cam cover
5. Cam cover seal
6. Camshaft oil seal
7. Front camshaft cap
8. VVT camshaft
9. Exhaust camshaft
10. Tappet
T1 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)

INSPECTION
TAPPET SELECTION PROCEDURE
CAUTION :
(1) The tappet clearance measurements should only be done after a minimum 2 hours of soaking.
(2) Ensure that cam sprocket timing marks in line with cam cover timing marks (crank is 90° ATDC).
(3) Cylinder head must be clamped with cylinder block to get achieve precise tappet clearance
measurement.
(4) Rotate cam sprocket clockwise direction as below sequence and measure the clearance using
thickness gauge.
Side Cam rotation Cam lobe number measurement

0° 1&2
90° 5&6
Inlet
180° 7&8
270° 3&4
0° 5&6
90° 7&8
Exhaust
180° 3&4
270° 1&2
(5) Measure clearances X and Y (16 places) using a thickness gauge.
X = 0.2 ± 0.05
X = 0.3 ± 0.05
(6) If incorrect, select new tappets for correct clearance by using formula below.
Intake grade = Z + ( X – 0.2 )
Intake grade = Z + ( Y – 0.3 )
Symbol Description
(7) Remove camshafts and known tappets, lubricate selected grade of tappets with oil and locate
in cylinder head assy.
(8) Install camshafts and caps without using sealant on front caps.
(9) Verify clearance X and Y (16 places) using a thickness gauge.
(10) Apply sealant as shown and install front caps.
(11) The sequence to secure camshaft front cap and camshaft intermediate cap as below :

Cam cap inlet I3 I4 I2 I5 I1
Cam cap exhaust E3 E4 E2 E5 E1

DOINE11AR11116
Symbol Description
A Intake camshaft
B Exhaust camshaft
C Tappets
D Cylinder head assy

DOINE11AR10012
1. STEP 1
1.1 Align markings (A) at VVT sprocket and exhaust camshaft sprocket to the cam cover top
marking 0°( 12 o’clock ) as shown in the illustration.
Symbol Description
I Intake side
E Exhaust side
camshaft lobe :

0°
(12 o’clock)

DOINE11AR11163
2. STEP 2
Symbol Description
I Intake side
E Exhaust side

90°
(3 o’clock)

DOINE11AR11004
3. STEP 3
Symbol Description
I Intake side
E Exhaust side

180°
(6 o’clock)

DOINE11AR11005
4. STEP 4
Symbol Description
I Intake side
E Exhaust side

270°
(9 o’clock)
5. Note all 16 pieces tappet clearance as shown in table below.

1 X1
2 X2
3 X3
4 X4


5 X5
6 X6
7 X7
8 X8
Tappet No. Tappet clearance measurement, Y (exhaust)
1 Y1
2 Y2
3 Y3
4 Y4
5 Y5
6 Y6
7 Y7
8 Y8
CAMSHAFT BEARING CAP REMOVAL

1. Loosen all bearing caps bolts based on the
loosening sequence as shown in the illustra-
tion.
Symbol Description
I Intake side
E Exhaust side
DOINE11AR11064
TAPPET REMOVAL
1. Remove tappets using magnet tool (A).
CAUTION :
Do not mix the original tappet position.
DOIGE11AR03052

2. Refer tappet grade at all tappets as shown

in the illustration (inside the tappet).
3. Note all tappets grade in table below.
DOINE11AR11063
Tappet No. Tappet grade dimension Z (intake)

1 Z1
2 Z2
3 Z3
4 Z4
5 Z5
6 Z6
7 Z7
8 Z8
Tappet No. Tappet grade dimension Z (exhaust)
1 Z1
2 Z2
3 Z3
4 Z4
5 Z5
6 Z6
7 Z7
8 Z8

TAPPET INSTALLATION
1. Refer table below for tappet clearance spe-
cification.
DOIGE11AR03122
Type Tappet clearance specification

Intake X = 0.2 mm ± 0.05 mm
Exhaust Y = 0.3 mm ± 0.05 mm

Tappet clearance measurement Clearance specification Description

X1 0.23 mm Reuse old tappet
X1 < 0.17 mm Replace with new tappet
X1 > 0.23 mm Replace with new tappet
2. Refer formula below for intake and exhaust
tappet grade identification.
Intake Grade :
Z + ( X – 0.2 mm )
Exhaust Grade :
Z + ( Y – 0.3 mm )
Symbol Description ( in mm)

FOR EXAMPLE, THE CALCULATION BELOW
SHOWS THE INTAKE TAPPET GRADE SELECTION.
Z + (X – 0.2mm) : 3.000 + (0.3 – 0.2)
: 3.000 + (0.1)
: 3.100 mm
Due to 3.100 mm is very close to 3.105 mm, select
tappet grade 08

01 3.000
02 3.015
03 3.030
04 3.045
05 3.060
06 3.075
07 3.090
08 3.105
09 3.120
10 3.135
11 3.150
12 3.165
13 3.180
14 3.195
15 3.210
16 3.225
17 3.240
18 3.255
19 3.270
20 3.285
21 3.300


22 3.315
23 3.330
24 3.345
25 3.360
26 3.375
27 3.390
28 3.405
29 3.420
30 3.435
31 3.450
32 3.465
33 3.480
34 3.495
35 3.510
36 3.525
37 3.540
38 3.555
39 3.570
40 3.585
41 3.600
42 3.615
43 3.630
44 3.645
45 3.660
46 3.675
47 3.690
oil on the tappet and insert all tappets inside
cylinder head assy.
DOINE11AR11066

1. Apply engine oil to the camshafts.
Be careful not to confuse the VVT camshaft
with the exhaust camshaft.
Symbol Description
A VVT camshaft
Half moon shape at end portion
B
of VVT camshaft.
DOINE11AR11067
CAMSHAFT BEARING CAP INSTALLATION

1. Surface should be clean, dry and free from
grease and debris.
2. Apply sealant on front camshaft bearing cap
Specified sealant :
TB1110B 2 mm (0.079 in) bead size.
Symbol Description
DOINE11AR11062
3. Before installing the other bearing caps, ar-

range the bearing caps by referring the
stamped identification marking on each the
bearing caps.
Identifica-
tion mark- Description
ing
A I (Intake side), E (exhaust side)
B Bearing caps number
C Arrow facing to timing belt
side
DOIGE11AR03056

4. Tighten bearing caps bolt using the following

tightening sequence order.

VVT cam-
I3 I4 I2 I5 I1
shaft cap
Exhaust
camshaft E3 E4 E2 E5 E1
cap
Steps Operation
Tighten camshaft caps in se-
quence using minimum force
S1
leaving an even gap between
cam caps and cylinder head.
Tighten camshaft cap evenly in
S2
sequence until the gap is closed
Tighten camshaft cap in se-
quence order to the specified
S3 torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 -
7.96 ft.lbs)
Symbol Description
DOINE11AR11060
B Leave even gap
C Bearing cap intermediate
I Intake side
E Exhaust side
NOTE :
Do not splash engine oil on the VVT camshaft
and exhaust camshaft cap cylinder head area.
5. Verify again all 16 pieces tappets clearance
Symbol Description
A Thickness gauge
B Camshaft lobe
6. If the tappets clearance is not within tappet
clearance specification , remove again all
camshaft bearing caps and select the correct
new tappet.
DOINE11AR10013

VVT CAMSHAFT OIL SEAL INSTALLATION

2. Install special tool (inner) at the VVT cam-
shaft as shown in the illustration.
Symbol Description
A Special tool EZT 0006 (inner)
B VVT camshaft
C Oil seal housing
DOINE11AR11176
3. Securely insert new oil seal through the spe-

cial tool (inner).
Symbol Description
A Oil seal
DOINE11AR11177
4. Slowly and carefully knock the oil seal by

using special tool (outer).
5. Then, remove the special tool (inner) and
continue knocking the oil seal until it prop-
erly fitted at oil seal housing by using the
special tool (outer).
Symbol Description
A Oil seal
B Special tool EZT 0006 (outer)
C Mallet
DOINE11AR11178

EXHAUST CAMSHAFT OIL SEAL

INSTALLATION
2. Insert oil seal into the special tool (inner) and
then by using another part of the special tool
(outer), knock in the oil seal carefully using
mallet as shown in the illustration.
Symbol Description
A Oil seal housing
C Special tool EZT 0006 (outer)
D Mallet
E Oil seal
CAUTION :
Do not damage the oil seal during installa-
tion.
DOINE11AR11179
OIL FILLER CAP INSTALLATION

Clean oil cap and cam cover sealing face from oil
trace/debris using soft cloth during oil change
or oil top-up.
DOINE11AR11065

INSPECTION
CAMSHAFT
Measure the cam heights and replace the cam-
shaft if any height exceeds the specified limit.
Identification
Standard value
mark
Limit Value
Symbol Description
A Cam lobes heights measurement
B Micro meter
C Cam position lobes measurement
D Camshaft
DOIGE11AR06170

CYLINDER HEAD AND VALVES / 77
CYLINDER HEAD AND VALVES WEO11ASASSY10014
DOIGE11AR03059

/ 78 CYLINDER HEAD AND VALVES
— Lubricate all internal parts with engine oil during reassembly

Removal steps :
1. Cylinder head bolt
2. Cylinder head assembly
3. Cylinder head gasket
4. Intake valve collet
5. Intake valve spring retainer
6. Intake valve spring
7. Intake valve
8. Exhaust valve collet
9. Exhaust valve spring retainer
10. Exhaust valve spring
11. Exhaust valve
12. Intake valve stem seal and spring seat
13. Exhaust valve stem seal and spring seat
14. Intake valve guide
15. Exhaust valve guide
16. Intake valve seat
17. Exhaust valve seat
18. Cylinder head
Steps Value Remarks
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.2 kgm (2 • One bolt at a time
A
Nm, 1.45 ft.lbs) • Follow sequence No.1 to 10
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm (2 for step A, B and C.
B • Repeat each step until all
Nm, 1.45 ft.lbs)
bolts achieve specification.
C 90° (Min)
D 90° (Min)


1. Use special tool to loose the bolts in se-
quence order and then use hand to untight-
en completely the bolts as shown in the illus-
tration.
2. After loosening all bolts engine, remove the
cylinder head assy from engine.
CAUTION :
The plug guides cannot be replaced or change,
be careful not to damage or deform the plug
guides when removing the cylinder head bolts.
Symbol Description
DOIGE11AR03143
VALVE COLLET REMOVAL

1. Locate cylinder head assy on top of the spe-
cial tool as shown in the illustration.
Symbol Description
A Cylinder head assy
DOIME11AR11024
2. Before using special tool, ensure the special

tool stopper is located at the shown location.
Symbol Description
B Special tool (EZT 0002) stopper
DOINE11AR11164

3. Knock the valve spring retainer with mallet

in order to remove valve collet.
Symbol Description
A Cylinder head assy
DOIME11AR11025
4. Remove valve collet from special tool at the

shown location.
Symbol Description
A Valve collet
B EZT 0002
DOIME11AR11026
VALVE STEM SEAL AND SPRING SEAT

REMOVAL
1. Use special tool to remove valve steam seal
and spring seat.
Symbol Description
DOINE11AR11165


VALVE STEM SEAL AND SPRING SEAT
INSTALLATION
1. Use special tool to install the valve stem seal
and spring seat into the intake and exhaust
valve guide.
Symbol Description
A Valve stem seal and spring
seat
B Valve guide
CAUTION :
Do not reuse the removed valve stem seals.
DOINE11AR11166
INTAKE VALVE AND EXHAUST VALVE

INSTALLATION
1. Apply engine oil to the intake valve and ex-
haust valve.
2. Install the intake valve and exhaust valve to
the cylinder head side.
Symbol Description
C Intake or exhaust valve
DOIGE11AR03125

VALVE SPRING INSTALLATION

1. Install intake valve and exhaust valve into
cylinder head, then locate on the special tool
Symbol Description
Intake valve and exhaust
B
valve
C Cylinder head
DOINE11AR11167
2. Locate valve spring on intake valve or ex-

haust valve.
3. Align and locate valve spring retainer over
intake valve or exhaust valve.
Symbol Description
D Valve spring
E Valve spring retainer
DOIGE11AR03126
VALVE COLLET INSTALLATION

1. Insert the valve collet to the special tool as
Symbol Description
1 Bigger semi circumference
2 Smaller semi circumference
CAUTION:
Make sure the smaller semi circumference
facing outward when inserting the collet
DOIGE11AR03063
into the special tool.

2. Be careful to press down the special tool (EZT

0001) until ‘click’ sound is heard.
Remove special tool and check the valve col-
lets position. Make sure the valve collets are
fix securely into it's position.
Symbol Description
F Valve collets
DOIME11AR11030
3. Put out the special tool (EZT 0046), then

knock the valve use roll bar to make sure
valve collets is properly fixed in it’s position.
DOIME11AR11031

place the bolt.
Specification :
160 mm (6.3 in) ± 0.35 mm (0.014 in)

washers.
DOIGE11AR03065


Symbol Description
DOIGE11AR03066

Steps Value Remarks
2.0 kgm (20 Nm, 14.47 ft.lbs) ± 0.2 kgm
A • One bolt at time.
(2 Nm, 1.45 ft.lbs)
3.0 kgm (30 Nm, 21.7 ft.lbs) ± 0.2 kgm • Follow sequence No. 1 to 10 for steps
B A, B, & C.
(2 Nm, 1.45 ft.lbs)
• Repeat each step until all bolts achieve
C 90° (Min) specification.
D 90° (Min)
5. By using special tool (Mot.591.04), tighten
all bolts to the specified torque.
Symbol Description
A Special tool (Mot.591.04)
DOINE11AR11168
INSPECTION
CYLINDER HEAD
1. Check the cylinder head gasket surface for
flatness by using a straightedge and thickness
gauge.
Standard value :
0.1 mm (0.004 in)
2. If the service limit is exceeded, correct to

meet the specification.
Grinding limit :
DOIIE11AR9066 * 0.2 mm (0.008 in)
*Includes / combined with cylinder block

grinding

Cylinder head height (Specification when

new) :
134.7 mm (5.3 in) ± 0.1 mm (0.004 in)
VALVE
1. Check the valve face for correct contact. If
incorrect, reface using a valve refacer. Valve
should make a uniform contact with the seat
at the centre of valve face.
2. If the margin (B) is smaller than the service
limit, replace the valve.
Standard value :
Intake : 1.5 mm (0.059 in) ± 0.15 mm (0.006
in)
Exhaust : 1.95 mm (0.077 in) ± 0.15 mm
(0.006 in)
DOIIE11AR9067
3. Measure the valve total length. If the meas-

urement is less than the specified valve, re-
place the valve.
Items Standard
103.53 mm (4.08 in) ± 0.20 mm
Intake
(0.008 in)
102.28 mm (4.03 in) ± 0.20 mm
Exhaust
(0.008 in)
VALVE SPRING
1. Measure the valve spring free height. If the
height is less than the limit value, replace the
valve spring.
Standard value :
38.17 mm (1.5 in)
Limit :
37.17 mm (1.46 in)
Symbol Description
DOIGE11AR06173 A Valve spring
B Vernier caliper

2. Place the spring on a flat surface next to a

steel square. Rotate the spring while check-
ing for a gap between the side of the spring
and the steel square.
3. Measure the squareness of the valve spring
and if the limit is exceeding the limit value,
replace the valve spring.
Standard value :
1 mm or less
Limit :
2 mm
DOIGE11AR06172
Symbol Description
C Squareness
D Valve spring
E Steel square

NOTE

/ 88 OIL PUMP AND OIL PAN
OIL PUMP AND OIL PAN WEO11ASASSY10015
DOINE11AR11095

OIL PUMP AND OIL PAN / 89
— Sealant
— Apply engine oil to all moving parts before installation
Removal steps :
1. Oil filter 14. Front oil seal
2. Oil drain plug 15. Front case
3. Gasket 16. Front case seal
4. Crank angle sensor 17. Oil pump backplate
5. Oil pan 18. Oil pump inner rotor
6. 19. Oil pump outer rotor
Windage tray
7. 20. Stud (Special)
Baffle
8. Oil pick up pipe
9. Oil seal
10. Relief valve plug
11. Relief valve seal
12. Relief valve spring
13. Relief valve piston
T1 : 0.8 - 1.2 kgm (8 - 12 Nm, 5.79 - 8.68 ft.lbs)
T4 : 0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
T8 : 1.2-1.6 kgm (12-16 Nm, 8.68-11.57 ft.lbs)

REMOVAL SERVICE POINT WEO11ASPROC10013
OIL PAN REMOVAL

DOIME11AR11034

Symbol Description
ations shown.
B Oil pan
DOIME11AR11033

CAUTION :
oil pan flange.
DOIME11AR11035


FRONT CASE INSTALLATION
1. Clean the surfaces on the cylinder block and
front case surfaces.
2. Locate front case seal in front case groove.
Symbol Description
A Front case seal
3. Align the oil pump rotor back plate to the
crankshaft.
DOINE11AR11130 4. Align dowel holes to the dowels at cylinder
block.
5. Fix the front case to cylinder block properly.
FRONT OIL SEAL INSTALLATION

1. Place the special tool on the crankshaft's
front end and apply engine oil to its outer
circumference.
DOIGE11AR03099
2. Apply engine oil to the oil seal lip, then push

the oil seal along the guide by hand until it
touches the front case. Tap the oil seal into
place by using the special tool.
DOIGE11AR03100


1. Slowly insert the oil pick up pipe oil seal to
the oil pan hole. Carefully do not damage
peating step no.1.
DOIGE11AR03112 specified torque.
1.45 ft.lbs)

0.72 ft.lbs)
Symbol Description
A Baffle
DOINE11AR11088
5. Tighten the windage tray bolts in the se-

quence order to the specified torque.
Specified torque :
0.72 ft.lbs)
Symbol Description
A Windage tray
DOINE11AR11089


2. Apply a 3 mm (0.12 in) ± 1 mm (0.039 in)
Symbol Description
A Bolt hole
Specified sealant :
TB1207F).

0.9-1.1 kgm (9-11 Nm, 6.51-7.96 ft.lbs)
DOINE11AR11087

front case.
Symbol Description
A Oil filter o-ring
DOIGE11AR03111


Specified torque (T8) : 1.2 - 1.6 kgm (12 - 16
Nm, 8.68 - 11.57 ft.lbs)
DOIGE11AR03071
CRANK ANGLE SENSOR INSTALLATION

1. Apply soap water to crank angle sensor and
tighten the crank sensor screw by using torx
0.72 ft.lbs)
Symbol Description
A Crank angle sensor
DOIGE11AR03072
B Target wheel
C Screw special
INSPECTION
OIL PUMP
1. Fit the oil pump rotors into the front case.
2. Check the tip clearance using a thickness
gauge.
Standard value :
0.06 - 0.18 mm (0.002 - 0.007 in)
Symbol Description
A Oil pump rotors
DOINE11AR11169
B Front case
C Thickness gauge

3. Check the side clearance using a straight

edge and thickness gauge.
Standard value :
0.03 - 0.10 mm (0.001 - 0.004 in)
Symbol Description
A Oil pump rotors
B Straight edge
C Thickness gauge
DOINE11AR11170
4. Check the body clearance using a thickness

gauge.
Standard value :
0.04 - 0.10 mm (0.002 - 0.004 in)
Limit :
0.35 mm (0.014 in)
Symbol Description
A Oil pump rotors
B Front case
DOINE11AR11171 C Thickness gauge

/ 96 PISTON AND CONNECTING RODS
PISTON AND CONNECTING RODS WEO11ASASSY10017
DOINE11AR11152

PISTON AND CONNECTING RODS / 97
— Apply engine oil to all moving parts before installation

Removal steps :
1. Connecting rod bolt
2. Connecting rod cap
3. Connecting rod bearing
4. Piston and connecting rod assembly
5. Connecting rod bearing
6. Piston ring No.1
7. Piston ring No.2
8. Oil ring
9. Piston pin circlip
10. Piston pin
11. Piston
12. Connecting rod

CONNECTING ROD CAP REMOVAL

1. Indicate a marking at the side of the connect-
ing rod big end as shown in the illustration.
CAUTION :
To facilitate reassembly, please do not punch
the connecting rod.
DOIME11AR11056
2. Remove the connecting rod caps bolts and

then remove the connecting rod cap.
Symbol Description
A Crankshaft
B Connecting rod cap
DOIME11AR11057
CONNECTING ROD, PISTON PIN AND PISTON

REMOVAL
1. Insert special tool into the connecting rod
and then remove the connecting rod prop-
erly from cylinder block.
CAUTION :
Do not scratch the crankshaft surface.
Symbol Description
A EZT 0008
DOIME11AR11058
2. NOTE :
1) Due to piston pin circlip position is differ-
ent for ‘FRONT’ and ‘REAR’ side, only remove
the ‘FRONT’ side piston pin circlip as shown
2) If reused the piston and piston pin, the
piston pin circlip at ‘REAR’ side must be re-
moved . In order to remove the circlip, care-
fully push the circlip open end to 12 o’clock
or 6 o’clock before removing the circlip using
small screw driver.
DOINE11AR11180

Symbol Description
A Piston pin circlip
B Piston ‘FRONT’ side mark
By using small screw driver, carefully pry-out
the piston pin circlip from connecting rod
pin oil groove as shown in the illustration.
CAUTION :
Do not scratch the piston circlip housing
surface.
Symbol Description
A Connecting rod
B Piston pin circlip
C Small screw driver
DOINE11AR11173 D Pin oil groove
3. Pull out piston pin from piston and connect-
ing rod.
Symbol Description
A Piston pin
B Piston
C Connecting rod
DOINE11AR11102
4. If the part is in good condition, keep the

piston, piston pin, and connecting rod togeth-
er. Do not mix-up pistons, piston pins, and
connecting rods from different cylinders.
DOINE11AR11100

INSPECTION WEO11ASPROC10017
PISTON RINGS
1. Check the piston ring side clearance. If the
clearance exceeds the specified limit, replace
the ring or piston, or booth.
Standard value :
No. 1 ring : 0.03-0.05 mm (0.001-0.002 in)
No. 2 ring : 0.02-0.04 mm (0.001-0.002 in)
DOIIE11AR9087
2. Insert the piston ring into the cylinder bore

and push it down with a piston (A). Ensure
that the piston's crown is in contact with the
ring such that the ring is at 90° to the cylin-
der wall. Then, measure the end gap (C) with
a thickness gauge. If the gap is too large,
replace the piston ring (B).
Standard values :
No. 1 ring : 0.20-0.35 mm (0.008-0.014 in)
No. 2 ring : 0.37-0.57 mm (0.015-0.022 in)
Oil ring : 0.2-0.5 mm (0.008-0.02 in)
DOIGE11AR03076 Limits :
No. 1 ring : 0.5 mm (0.02 in)
No. 2 ring : 0.75 mm (0.03 in)
Oil ring : 1.0 mm (0.039 in)
CRANKSHAFT PIN OIL CLEARANCE (PLASTIC

GAUGE METHOD)
1. Wipe all oil off the crankshaft pin and con-
necting rod bearing.
2. On the pin, place a plastic gauge that is cut
to the same length as the bearing's width.
The plastic gauge must be centered on the
pin in parallel with the pin's axis.
3. Gently place the connecting rod cap in posi-
tion and tighten the bolts to the specified
torque.
4. Remove the bolts and gently remove the
DOIIE11AR9089
connecting rod cap.
5. Measure the compressed part of the plastic
gauge at its widest point using the scale
printed on the plastic gauge bag.
Standard value :
0.02-0.044 mm (0.001-0.002 in)
Limit :
0.1 mm (0.004 in)


WEO11ASPROC10018
PISTON / PISTON PIN AND CONNECTING

ROD INSTALLATION
1. Refer cylinder bore identification marks at
cylinder block top surface as shown in the il-
lustration.
2. Select correct piston size according to the
cylinder bore identification mark. The piston
size outer diameter identification mark is
painted on top of piston surface. Ensure that
marks are same as cylinder bore identifica-
tion mark.
For example,
Cylinder
bore identi-
A B A A
fication
mark
Piston size
outer dia-
meter identi- A B A A
fication
mark
DOINE11AR11111
3. CAUTION :
By using air gun, clean piston, piston pin and
piston pin circlip groove in order to remove
all dust and chips.
Before installing the piston to the connecting
rod, ensure the ‘DOT’ marking at piston and
connecting rod are facing in same direction
Symbol Description
A ‘ DOT’ marking
B Piston
DOINE11AR11105
C Connecting rod
4. Prior to the installation of piston pin, apply
a sufficient amount of lubrication to the
outer surface pin and small end bore of the
connecting rod.
Lubrication type : Engine oil or non-water
soluble press oil (Yugen Kugyo Standards
DS-711 or equivalent)
DOINE11AR11106

5. Press the piston pin through the connecting

rod small end bore until it is stopped by
circlip located at the other side of piston
bore.
DOINE11AR11107
6. Insert piston pin circlip into piston pin groove

by positioning the open end circlip at 12
o’clock direction as shown in the illustration.
NOTE :
If install new piston pin circlip at ‘REAR’ side
piston, ensure the piston pin circlip is in-
stalled at 12 o’clock position as shown in the
illustration.
Symbol Description
A Piston pin circlip
DOINE11AR11181
B Piston ‘FRONT’ mark
CAUTION :
(1) The circlip can only be reused until 3
times removal only.
(2) Do not use the piston and connecting
rod assy if additional load is required to
insert pin into the piston.
(3) When installing the piston pin, be sure
to keep the piston pin square with the
small end bore of the connecting rod.
(4) When reinstalling the piston pin, make
sure that the clearance fit is within the
specification as shown in the table be-
low.
Connect-
Piston Pin ing rod Clearance
Lenght of
outside small end (calcu-
Pin
diameter inside dia- lated)
meter
Ø19 ( 0, - 19.012 ± 0.007 – 54 ( 0, -
0.005 ) 0.005 0.022 0.3 )

7. Carefully, press-in the piston pin circlip by

hand and then push-in the circlip by using
small screw driver.
Symbol Description
A Connecting rod
B Piston pin circlip
C Small screw driver
D Pin oil groove
CAUTION :
Use cloth to cover the circlip during installa-
DOINE11AR11182 tion in order to avoid the circlip missing.
OIL CONTROL RING INSTALLATION

1. Fit the oil control ring spacer into the piston
ring groove. Then, fit the upper and lower
side rails.
Symbol Description
A Upper and lower side rails
B Oil control ring spacer
1 Groove ring compression top
2 Groove ring compression
second
NOTE :
(1) Apply minimum engine oil at the groove.
(2) The spacer and side rails are reversible.
Spacer and side rail sizes are color-coded as
follows :
Part Colour
Gap clearance
name mark
0.2 kgm (2 Nm, 1.45
Side rails None ft.lbs) ± 0.005 kgm (0.05
Nm, 0.036 ft.lbs)
0.02 - 0.05 kgm (0.2 - 0.5
Spacer White
Nm, 0.14 - 0.36 ft.lbs)
DOINE11AR11112
2. To install a side rail, fit one end of the rail

(C) into the groove then press the rest of the
rail into position by hand as shown in the il-
lustration.
CAUTION :
Do not fit side rails using a piston ring ex-
pander as they may break.
3. After installing 3 pieces of oil ring, check the
upper and lower side rails condition and en-
sure it can be turned smoothly.
DOIIE11AR9094

COMPRESSION TOP RING (1R) /

COMPRESSION SECOND RING (2R) INSTALLATION
1. Using a ring expander, fit the piston ring No.
2 and ring No. 1 with their identification
marks facing upward (on the piston crown
side).
Symbol Description
A Ring expander
DOIIE11AR9095
2. Refer table below for identification paint

marks on piston rings.
Symbol Part name Color paint

Compression
A Yellow
top ring
Compression
B Blue
second ring
DOINE11AR11110
3. Refer table below for identification stamping

marks on piston rings.
I.D mark Part name Gap clearance

Compres-
0.2 - 0.35 mm
1R sion top
(0.008 - 0.014 in)
ring
Compres-
0.37 - 0.57 mm
2R sion second
(0.015 - 0.022 in)
ring
DOINE11AR11113
PISTON AND CONNECTING ROD ASSEMBLY

INSTALLATION
1. Remove connecting rod cap.
2. Select and install the proper connecting rod
bearing.
3. Set special tool for the piston insertion on
reamer bolt of the connecting rod.
Symbol Description
4. Apply engine oil to the piston rings, oil ring,
DOIGE11AR03161 connecting rod bearing, and cylinder bore.

CAUTION :
Ensure the cylinder bore is flawless. Else,
rebore it to the following specifications.
5. Align the gaps of the piston rings and oil ring
(side rails and spacer) as shown in the illustra-
tion.
Symbol Description
A Side rail (ring - oil - control)
B Ring - compression - top
C Ring - compression - second and
spacer (ring - oil - control)
D Piston pin
DOIIE11AR9097
6. Ensure all arrow marking on top of the pis-

tons are facing to timing belt side as shown
Symbol Description
Arrow marking facing timing
A
belt side
DOINE11AR11174

7. Compress the piston rings tightly with a

suitable ring compression tool, then press
the piston and connecting rod assembly fully
into the cylinder bore. Do not strike the pis-
ton hard since the piston rings may break
and the crank pin may be nicked.
NOTE :
(1) Ensure that the identification marks on
the piston crown coincide with those on
the cylinder block top surface.
(2) Ensure the ‘←’ mark is facing to timing
belt side.
DOIIE11AR9098
(3) Ensure to make the notch by the locking
around the bearing on the same time
8. Remove the special tool ( EZT0008 ) from
connecting rod.
9. Install and pre-tighten bolt connecting rod
by hand. Then, tighten to the specified
torque.
Specified torque :
2.2 kgm (22 Nm, 15.91 ft.lbs) + 90°
CONNECTING ROD BEARING INSTALLATION

1. Select bearings according to the crankshaft
and connecting rod identification marks or
color codes.
Symbol Description
P Pin number for con rod bearing
IM Con rod bearing identification
mark position
A Con rod bearing
DOINE11AR11117

BEARING SELECTION TABLE

CRANKSHAFT & CON ROD COMBINATION
Crankshaft identific- Con rod / bore identifica- Bearing selected Oil clearance (mm)
ation mark tion mark
A 1 0.020 – 0.036
1 B 1 0.024 – 0.044
C 2 0.024 – 0.040
A 1 0.024 – 0.044
2 B 2 0.020 – 0.044
C 3 0.020 – 0.040
A 2 0.024 – 0.040
3 B 3 0.020 – 0.040
C 3 0.028 – 0.044
2. The connecting rod identification mark is
stamped at big end bore portion as shown
Symbol Description
A Big end bore identification mark
DOIME11AR11040
3. The connecting rod bearing identification

mark is painted on the bearing top surface
Symbol Description
A Identification mark
4. The example to select the correct connecting
rod bearing is shown in table below.
Crankshaft identific-
ation mark (pin no.1 2 1 1 2
until pin no.4)
DOINE11AR11175 Connecting rod
identification mark A C B B
(example)
Select correct con-
necting rod bearing 1 2 1 2
number

CONNECTING ROD CAP INSTALLATION

1. Aligning the marks made during disassembly,
fit the bearing cap onto the connecting rod.
If the connecting rod is new and has no index
mark, ensure that the front marks on the
connecting rod and connecting rod cap are
on the same side.
Symbol Description
A Front marks
DOIME11AR11041
2. Check that the connecting rod big end side

clearance confirms with specifications.
Standard value :
0.10 - 0.25 mm (0.004 - 0.01 in)
Limit:
0.4 mm (0.016 in)
DOIGE11AR03085
CONNECTING ROD BOLT INSTALLATION

CAUTION :
To fit the connecting rod bolts with the cylinder
head in place, the spark plugs must be removed
beforehand.
1. Pre-tighten all the connecting rod cap bolts.
2. Tighten the bolts to the specified torque.
Specified torque :
2.2 kgm (22 Nm, 15.91 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
DOIGE11AR03086
3. Then, using the special tool ( Mot.59104 ),
tighten the connecting rod bolts according
to the specified torque angle.
Torque angle :
90° ± 5°

CRANKSHAFT AND CYLINDER BLOCK / 109
CRANKSHAFT AND CYLINDER BLOCK WEO11ASASSY10018
DOINE11AR11131

/ 110 CRANKSHAFT AND CYLINDER BLOCK
— Sealant
— Patch Lock Screw (TB1300)
— Apply engine oil to all moving parts before installation.
Removal steps :
1. Direct damper flywheel (DDF) bolt 9. Crankshaft assy
2. Direct damper flywheel (DDF) 10. Crankshaft bearing (lower)
3. Rear plate 11. Bearing cap
4. Rear oil seal 12. Bearing cap bolts
13. Cylinder block
5. Rear oil seal case
14. Knock sensor
6. Crankshaft bushing
7. Target wheel 16. Oil jet
8. Crankshaft bearing (upper)
T2 : 0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
T3 : 2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
T4 : 8.0 - 9.0 kgm (80 - 90 Nm, 57.86 - 65.1 ft.lbs)
T5 : 4.91 - 5.39 kgm (49.1 - 53.9 Nm, 35.51 - 38.99 ft.lbs)

OIL PRESSURE SWITCH REMOVAL

1. Disconnect the oil pressure switch terminals.
2. By using the special tool (MD998054), remove
the oil pressure switch (A).
CAUTION :
Take care not to damage the oil pressure
switch when removing it.
DOINE11AR11153
DIRECT DAMPER FLYWHEEL (DDF)

REMOVAL
1. Lock the Direct Damper Flywheel (A) by using
special tool (B).
2. Then, loosen the 5 pieces bolts (C) as shown
Symbol Description
Direct Damper Flywheel
A
(DDF)
DOINE11AR11132
C Direct Damper Flywheel bolts

INSPECTION WEO11ASPROC10021
CRANKSHAFT OIL CLEARANCE

The crankshaft oil clearance can be measured
easily using a plastic gauge (A).
To check the crankshaft oil clearance with a
plastic gauge, carry out the following procedure:
1. Wipe all oil off the crankshaft journal and
the bearing's inside surface.
2. Install the crankshaft.
3. Cut the plastic gauge such that its length
DOIIE11AR9105 matches the width of the bearing, then place
it on the journal along the journal's axis.
4. Gently fit the crankshaft bearing cap and
tighten the bolt to the specified torque.
5. Remove the bolts and gently remove the
crankshaft bearing cap.
6. Using the scale printed on the plastic gauge
bag, measure the plastic gauge's crushed
section at its widest point.
Standard value :
0.018 - 0.036 mm (0.001 - 0.001 in)
Limit :
0.1 mm (0.004 in)
DOIIE11AR9106
NOTE :
The crankshaft pins and journals are fillet-rolled
(B) and must not be machined to undersize di-
mensions.
DOIIE11AR9107
CYLINDER BLOCK
1. Visually check for cracks, rust, and corrosion,
and inspect the cylinder block using a flaw
detecting agent. Rectify defects where pos-
sible or replace the cylinder block.
2. Ensure that the top surface is free of gasket
chips and other foreign material. Check the
cylinder block's top surface for distortion
using a straight edge and thickness gauge.
Standard value :
0.03 mm (0.001 in)
DOIIE11AR9108

Limit :
0.1 mm (0.004 in)
3. Check the cylinder walls for cracks and

seizure marks. If defects are evident, bore all
the cylinders to oversize or replace the cylin-
der block.
4. Using a cylinder gauge, measure each cylin-
der's bore and cylindricity. If any cylinder is
severely worn, bore all the cylinders to over-
size and replace the piston and piston rings
accordingly. Take measurements at the
points shown.
Standard value :
Cylinder bore : 76.0 mm (2.99 in)
Cylinder stroke : 86.0 mm (3.39 in)
Cylindricity : 0.025 mm (0.001 in) or less
DOIIE11AR06001
BORING CYLINDER
1. Oversize pistons to be used should be determ-
ined on the basis of the cylinder with the
largest bore.
2. Oversize pistons are available with the fol-
lowing oversize dimensions: 0.25 mm (0.01
in), and 0.50 mm (0.02 in), 0.75 mm (0.03 in)
and 1.00 mm (0.039 in). Measure the diamet-
er of the piston to be used. Boring must be
carried out such that the piston-to-cylinder
clearance complies with the standard value.
The piston 's diameter should be measured
DOIGE11AR03088
at the points shown.
3. Calculate the boring finish dimension based
on the piston diameter dimension.
• [Boring finish dimension] = [piston O.D. (A)]
+ [piston-to-cylinder clearance (0.01 - 0.03
mm (0 - 0.001 in))] – [honing margin (0.02
mm)]
4. Bore each cylinder to the calculate boring
finish dimension.
CAUTION :
To prevent distortion caused by heat in-
creases during boring, bore the cylinders in
the following order : No.2, No. 4, No. 1, No.
3.
5. Hone the cylinders to the final finish dimen-
sion (piston O.D. (A) + piston-to-cylinder
clearance).
6. Check the clearance between the pistons and
cylinders.

Standard value :
0.01 - 0.03 mm (0 - 0.001 in)

WEO11ASPROC10022
OIL PRESSURE SWITCH INSTALLATION

1. Apply the specified sealant to the thread of
oil pressure switch.
Specified sealant :
TB 1130
2. Use the special tool (MD998054) to tighten

the oil pressure switch to the specified
torque.
Specified torque :
1.45 ft.lbs)
3. Install the oil pressure switch terminal.

CAUTION :
• Apply sealant such that none is squeezed out
past end of the thread.
• Do not over-tighten the oil pressure switch.
DOIGE11AR03119
KNOCK SENSOR INSTALLATION

1. Install the knock sensor to cylinder block and
tighten the bolt flange
Specified torque :
2.2 - 2.6 kgm (22 - 26 Nm, 15.91 - 18.81 ft.lbs)
Symbol Description
A Knock sensor
NOTE :
The knock sensor terminal shall facing out-
DOIGE11AR03089 ward 90°.

PISTON COOLING JET INSTALLATION

1. Apply engine oil to the bolt thread and pis-
ton cooling jet.
2. Install piston cooling jet into cylinder block
assy.
3. Tighten the bolt to the specified torque.
Specified torque :
0.8 - 1.2 kgm (8 - 12 Nm, 5.79 - 8.68 ft.lbs)
DOINE11AR11068
CRANKSHAFT JOURNAL BEARING

INSTALLATION
1. Select bearings according to the crankshaft
identification marks. If they are not identifi-
able, measure the crankshaft journals and
choose bearings to match the measurements.
Example : Shaft 1 + Bore 2 = Bearing 3.
Symbol Description
JR Journal
IM Identification mark positions
A Main bearing identification
mark position
B Con rod bearing identifica-
tion mark position
DOINE11AR11018

CRANKSHAFT JOURNAL CYLINDER BLOCK BEARING SELECTED
Crankshaft Bearing iden- OIL CLEAR-
Outer diamet- Bore identi- Inner diamet- Bearing thick- ANCE (mm)
identifica- tification
er (mm) fication mark er (mm) ness (mm)
tion mark mark
0 52.000- 1 1.988-1.991 0.018 – 0.036
52.006
1 52.006- 2 1.991-1.994 0.018 – 0.036
1 47.994-48.000
52.012
2 52.012- 3 1.994-1.997 0.018 – 0.036
52.018


CRANKSHAFT JOURNAL CYLINDER BLOCK BEARING SELECTED
Crankshaft Bearing iden- OIL CLEAR-
Outer diamet- Bore identi- Inner diamet- Bearing thick- ANCE (mm)
identifica- tification
er (mm) fication mark er (mm) ness (mm)
tion mark mark
0 52.000- 2 1.991-1.994 0.018 – 0.036
52.006
1 52.006- 3 1.994-1.997 0.018 – 0.036
2 47.988-47.994
52.012
2 52.012- 4 1.997-2.000 0.018 – 0.036
52.018
0 52.000- 3 1.994-1.997 0.018 – 0.036
52.006
1 52.006- 4 1.997-2.000 0.018 – 0.036
3 47.982-47.988
52.012
2 52.012- 5 2.000-2.003 0.018 – 0.036
52.018
2. Identification marks showing the cylinder
block bearing bore diameter are stamped in
the position shown. Bearings must be selec-
ted and installed in accordance with these
identification marks.
Symbol Description
A First reading start from right
side to left side
B Timing belt side
C Cylinder block top surface
DOINE11AR11019
3. In order to select correct crankshaft main
bearing , refer the main bearing identifica-
tion mark at crankshaft and cylinder block.
For example,
At crankshaft
(journal no.1
2 3 3 2 2
until journal
no.5)
At cylinder
block (right side 1 2 0 2 2
to left side)
Select main
bearing identific- 3 5 3 4 4
ation number

4. The main bearing identification number is

painted on the main bearing outer surface
Symbol Description
B Painted identification mark
DOIGE11AR03083
5. Except for the center bearing, all the upper

bearings are grooved. The center bearings
are grooveless and have flanges. The center
bearings are the same at the top and bottom.
Symbol Description
E Grooveless (No groove)
F Gooved
Lower bearing (No. 1, 2, 3, 4
G
and 5)
Upper bearing (No. 1, 2, 4 and
H
DOINE11AR11183
5)
I Center upper bearing (No. 3)
6. The lower bearing are all grooveless.
BEARING CAP INSTALLATION

1. On the bottom surface of each bearing cap
is the cap's number and an arrow . Starting
at the timing belt side, fit the bearing caps
in numerical order. Ensure that the arrows
point towards the timing belt side.
2. Apply engine oil to the threaded portion and
bearing surface.
DOIGE11AR03093

3. Tighten the bearing cap bolts according to

tightening order as illustration.
Specified torque :
4.91 - 5.39 kgm (49.1 - 53.9 Nm, 35.51 - 38.99
ft.lbs)
DOIGE11AR03094
4. After fitting the bearing caps, measure the

end play at the crankshaft. If the measure-
ment exceeds the specified limit, replace the
crankshaft bearings.
Standard value :
0.07 - 0.195 mm (0.003 - 0.008 in)
Limit :
0.25 mm (0.01 in)
DOIGE11AR03116

REAR OIL SEAL INSTALLATION

1. Apply a small mount of engine oil to the en-
tire circumference of the oil seal lip.
the illustration.
Symbol Description
B Rear oil seal
D Mallet
DOIHC11AR04048

at the illustrated position (if it has no pre-
formed gasket attached)
Specified sealant :
CAUTION :

DIRECT DAMPER FLYWHEEL (DDF)

INSTALLATION
threaded portion, tightening bolts and from
2. Apply engine oil to the bolt flange and to
3. Apply sealant to the threaded portion of the
bolt ( if the bolt is reused ).
Specified sealant :
DOINE11AR11134
4. Install direct dual flywheel to the crankshaft
rear end as illustration and fit the bolt.
Symbol Description
A Cylinder block
B Direct damper flywheel (DDF)
C Direct damper flywheel bolt
1. Using the flywheel stopper to secure direct
damper flywheel and then tighten the direct
damper flywheel bolts to the specified
torque.
Service tightening torque :
8.0 - 9.0 kgm (80 - 90 Nm, 57.86 - 65.1 ft.lbs)
Symbol Description
A Direct damper flywheel (DDF)
C Direct damper flywheel bolt
DOINE11AR11132 2. Lock the Direct Damper Flywheel (A) by using
special tool (B).
3. Then, loosen the 5 pieces bolts (C) as shown

POINTS WEO11ASPROC10023
TARGET WHEEL REMOVAL

1. Insert an equivalent size of rubber pad into
the vice to avoid the crankshaft journal from
scratch as shown in the illustration.
Symbol Description
A Vice
B Rubber pad
DOIGE11AR09002

2. During fixing the crankshaft at vice, make

sure the rubber pad is firmly hold at the
crankshaft.
Symbol Description
A Vice
B Rubber pad
C Target wheel
D Crankshaft
DOIGE11AR09003
3. Clean the target wheel surface and patch

lock screw properly.
Steps Description
Spray an anti-rust to remove
A
any rust or dirt on the surface.
Use compress air to blow and
B
clean the surface.
Wipe with cloth to ensure the
C patch lock allen key head is
free from any rust or dirt.
DOIGE11AR09010
4. Use a ratchet together with an allen key to

remove 3 pieces of patch lock screws from
the target wheel.
CAUTION :
• It is highly recomended to use socket type
allen key to prevent any damage on the
patch lock allen key head.
• Ensure patch lock allen key head is clean
before removal.
Symbol Description
C Target wheel
DOIGE11AR09007

Symbol Description
D Crankshaft
E Socket with allen key
F Patch lock screw
G Ratchet
TARGET WHEEL INSTALLATION

Install new patch lock screw into target wheel
with the specified torque as shown in the illustra-
tion.
Specified torque :
0.9 - 1.1 kgm (9 - 11 Nm, 6.51 - 7.96 ft.lbs)
Symbol Description
C Target wheel
D Crankshaft
DOIGE11AR09007 E Socket with allen key
F Patch lock screw
G Ratchet

S4P Model YR 2011 English Edition RDCE-110S4P020-04 November 2011 Printed in Malaysia
WORKSHOP MANUAL
TRANSMISSION & CLUTCH OVER-
HAUL
CVT
Model YR 2011
English Edition RDCE-11PNCH080-00
Destination: ALL
July 2011 Printed in Malaysia
Copyright ©
Perusahaan Otomobil
Nasional Sdn. Bhd.
Printed in Malaysia 12 July 2011 Eng
WORKSHOP MANUAL -
Group Index /I
00 GENERAL ..................................................................................... 00/1 - 00/6

23C CONTINUOUSLY VARIABLE TRANSMISSION <CVT2 & CVT3> .... 23C/1 - 23C/29

- WORKSHOP MANUAL
/ II Group Index
NOTE

GENERAL 00
Content /1
00 GENERAL
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
DEFINITION OF TERMS ............................................................ 00/2
STANDARD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2
REFERENCE VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/2

00 GENERAL
HOW TO USE THIS MANUAL WTC000READS11001

This manual provides explanations concerning the inspection, checking, adjustment, disassembly and
reassembly of the engine, transmission and major components after they have been removed from
the vehicle.
ON-VEHICLE SERVICE
“On - Vehicle Service” is procedures for performing inspections and adjustments of particularly im-
portant locations with regard to the construction and for maintenance and servicing, but other inspec-
tion (for looseness, play, cracking, damage and etc.) must also be performed.
INSPECTION
Under this title are presented inspection and checking procedures to be performed by using special
tools and measuring instruments and by feeling but for actual maintenance and servicing procedures,
visual inspections should always be performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value as the standard for judging the quality of a part of assembly on inspection or the
value to which the part or assembly is corrected and adjusted. It is given by tolerance
LIMIT
It is a value established outside the range of standard value
REFERENCE VALUE
CAUTION
The tightening torque shown in this manual is a basic value with a tolerance of ±10% except the fol-
lowings cases when the upper and lower limits of tightening torque are given.
1. The tolerance of the basic value is within ±10%
2. Special bolts or the like are in use.

GENERAL 00
EXPLANATION OF MANUAL CONTENTS WTC000READS11002
DOIIC000R9001

00 GENERAL
SYMBOL DESCRIPTION
E Component Diagram
parts.
ing torque”

or type specified)
DOIIC000R9058
Sealant or adhesive
DOIIC000R9059

DOIIC000R9060

DOIIC000R9061

DOIIC000R9062
J
component parts.
Removal steps:
removal steps.

GENERAL 00
SYMBOL DESCRIPTION
Disassembly steps:
disassembly steps.
Installation steps:
Reassembly steps:

or disassembly.
DOIIC000R9052

or reassembly
DOIIC000R9051

DOIIC000R9053

and reassembly are described.

00 GENERAL
NOTE

CONTINUOUSLY VARIABLE TRANSMISSION <CVT2 & CVT3> 23C
Content /1
23C CONTINUOUSLY VARIABLE TRANSMISSION <CVT2 & CVT3>

GENERAL INTRODUCTION ........................................................... 23C/2
CVT CROSS-SECTION VIEW ....................................................... 23C/3
SPECIFICATIONS ....................................................................... 23C/4

GENERAL SPECIFICATIONS ........................................................ 23C/4
CVT 2 GEAR RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23C/4
CVT 3 GEAR RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23C/4
LUBRICANTS ......................................................................... 23C/4
TORQUE SPECIFICATIONS ......................................................... 23C/5
SPECIAL TOOLS ........................................................................ 23C/5

TOOLS ................................................................................. 23C/5
TRANSMISSION ........................................................................ 23C/8

DISASSEMBLY AND REASSEMBLY ................................................ 23C/8
DISASSEMBLY SERVICE POINTS ................................................... 23C/10
REASSEMBLY SERVICE POINTS .................................................... 23C/18

/2 GENERAL INTRODUCTION
GENERAL INTRODUCTION WTC23CGINFO001
The transmission's continuously variable ratio is achieved by means of a variator.

The variator consists of two cone pulleys located opposite to each other and a steel drive belt that
loops around the two pulleys like a V-belt.
The variator ratio is transmitted through an intermediate shaft to the differential incorporated into
the transmission housing.
This Student Information provides an overview of the transmission. The design and function of the
various assemblies of the transmission, the power of the transmission and the transmission control
are described individually. In addition, an overview is also provided for the transmission fluid cooling
system and the external gearshift mechanism. All spare parts and service tools are described, as well
as the error codes and actions to be carried out.
The stepless shifting pattern of the transmission provides a very comfortable drive, as well as having
full vehicle performance, available at any time.
The advantages of using an automatic transmission of this type are:
1. Low engine revolutions at constant speeds.
2. Improved emission control/fuel consumption.
3. Low noise, vibration and harshness levels.
4. Smooth acceleration.
5. Flexible driving on mountain roads.
Because of its fully electronic control the VT2/VT3 pushes the limits of its predecessor even further.

GENERAL INTRODUCTION /3
CVT CROSS-SECTION VIEW WTC23CGINFO002
DOINT23CR10024

/4 SPECIFICATIONS
Items 6. Steel belt

1. Torsional damper / flywheel 7. Primary pulley
2. Fluid pump 8. Secondary pulley
3. Reverse clutch 9. Intermediate shaft
4. Planetary gearing 10. Differential
5. Forward clutch
SPECIFICATIONS WTC23CSPECS001
Items Specification
Transmission Model PUNCH CVT
Transmission type CVT 2 and CVT 3
Torque converter type 3–element with torque converter clutch
Applicable engine S4PE and S4PH
CVT 2 GEAR RATIO
1.3 IAFM 1.6 IAFM
Gear
Min Max Min Max
CVT 2 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
CVT 3 GEAR RATIO
1.6 CFE
Gear
Min Max
CVT 3 0.46 2.55
SAT-1 2.42
SAT-2 1.28
SAT-3 0.90
SAT-4 0.70
SAT-5 0.55
SAT-6 0.46
Reverse 2.55
Final Drive 5.76
LUBRICANTS
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)

SPECIAL TOOLS /5
Items Value
Transmission Nut M8 self locking shift lever 1.45 kgm (14.5 Nm, 10.49 ft.lbs) ± 0.15 kgm (1.5
Nm, 1.08 ft.lbs)
Bolt primary cover M6X16 0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.25 kgm (2.5
Nm, 1.81 ft.lbs)
Flanged bolt oil pan M6X16 0.9 kgm (9 Nm, 6.51 ft.lbs) ± 0.1 kgm (1 Nm, 0.72
ft.lbs)
Bolt speed sensors 0.85 kgm (8.5 Nm, 6.15 ft.lbs) ± 0.2 kgm (2 Nm,
1.45 ft.lbs)
Bolt oil pump 1.0 kgm (10 Nm, 7.23 ft.lbs) ± 0.1 kgm (1 Nm,
0.72 ft.lbs)
Primary nut 19.75 kgm (197.5 Nm, 142.85 ft.lbs) ± 1.75 kgm
(17.5 Nm, 12.66 ft.lbs)
Plug M14 2.1 kgm (21 Nm, 15.19 ft.lbs) ± 0.3 kgm (3 Nm,
2.17 ft.lbs)
Plug M10 1.5 kgm (15 Nm, 10.85 ft.lbs) ± 0.22 kgm (2.2
Nm, 1.59 ft.lbs)
Countersunk head screw M6X16 0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.09 kgm (0.9
Nm, 0.65 ft.lbs)
Drain plug 1.1 kgm (11 Nm, 7.96 ft.lbs) ± 0.1 kgm (1 Nm,
0.72 ft.lbs)
Bolt valve body 1.1 kgm (11 Nm, 7.96 ft.lbs) ± 0.1 kgm (1 Nm,
0.72 ft.lbs)
Bolt position switch 0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.09 kgm (0.9
Nm, 0.65 ft.lbs)
Bolt bracket output speed sensor 0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.09 kgm (0.9
Nm, 0.65 ft.lbs)
SPECIAL TOOLS WTC23CSTOOL001
TOOLS
Mot. 1335 Circlip plier To lift out the pump
DOINT23CR10026
P480125 Stamp Oil seal selector shaft

installer
DOIIT23CR09003

/6 SPECIAL TOOLS

P480137 Stamp Primary bearing installer
DOIIT23CR09004
MD998350 Stamp Primary bearing installer
DOINT23CR11032
MD998348 Puller assembly Primary bearing re-

mover
DOINT23CR11030
MB991202 Primary bearing re-

mover
DOIMT22DR10152
P480130 Stamp Oil seal input shaft in-

staller
DOIIT23CR09006
P480129 Centering bush Oil seal input shaft in-

staller
DOIIT23CR09007
P480127 Removing tool Oil seal selector shaft

remover
DOIIT23CR09008

SPECIAL TOOLS /7

P480142 Centering pin To install hydraulic unit
DOIIT23CR09009
P480143 Stamp Install oil seal differen-

tial
DOIIT23CR09010

/8 TRANSMISSION
TRANSMISSION WTC23CSHAUL001
DOINT23CR11031

TRANSMISSION /9
— Non- reusable part

Disassembly steps
1. Input shaft plug 27. Input speed sensor (Primary speed sensor)
2. Oil seal input shaft 28. Output speed sensor bracket bolt (Secondary
3. Output shaft plug speed sensor bracket bolt)
4. Differential oil seal 29. Output speed sensor bracket (Secondary
5. Sealing ring plug M14 speed sensor bracket )
6. Plug M14 30. Output speed sensor (Secondary speed sensor)
7. Breather pipe with plug 31. Oil pan gasket
8. Breather cap 32. Cpl valve body (Hydraulic unit)
9. Clip (metal) 33. Valve body bolt
10. Breather pipe clip (plastic) 34. O-ring
11. Secondary cover o-ring 17.12X2.62 35. Oil filter
12. Secondary cover sealing ring 36. Magnet
13. Secondary cover o-ring 72.63X3.53 37. Oil pan assy
14. Secondary cover 38. Drain plug
15. Countersunk head screw M6X20 39. Position switch bolt
16. Primary ball bearing 40. Cpl position switch (Drive mode sensor)
17. Primary nut 41. O-ring
18. Belle-ville washer 42. Oil cooler connection plug
19. Sealing ring oil pump 43. Sealing ring
20. Oil pump o-ring 44. Plug
21. Oil pump 45. Cap connector protection
22. Oil pump bolt 46. Main connector clip
23. Primary cover o-ring 177,47X2.62 47. Main connector and internal harness cable
24. Primary cover 48. Shift lever
25. Primary cover clip 49. Nut
26. Bolt M6X16 50. Shift lever washer
51. Oil seal
T2 :0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.095 kgm (0.95 Nm, 0.69 ft.lbs)
T6 :0.85 kgm (8.5 Nm, 6.15 ft.lbs) ± 0.2 kgm (2 Nm, 1.45 ft.lbs)
T9 :1.5 kgm (15 Nm, 10.85 ft.lbs) ± 0.225 kgm (2.25 Nm, 1.63 ft.lbs)

/ 10 TRANSMISSION
DISASSEMBLY SERVICE POINTS

WTC23CSHAUL002
1. Use the screw driver to pinch out the oil dif-

ferential seal (LH and RH).
CAUTION
Be careful not to force the screw driver too
deep, to protect the housing from scratch or
damage.
DOINT23CR11019
2. Use the screw driver pinch out the oil seal

input shaft.
DOINT23CR10002
3. Remove the self locking nut shift lever.
DOINT23CR10003

TRANSMISSION / 11
4. Then remove the shift lever.
DOINT23CR10004
5. Place special tool P480127 on the selector

shaft , press and screw tool clockwise.
DOINT23CR11020
6. Rotate the screw to remove the oil seal.
DOINT23CR10005
7. Remove the primary cover bolts with clamp.
DOINT23CR10006

/ 12 TRANSMISSION
8. Use the screw driver pry primary cover.

NOTE
Use cloth to protect the transmission from
damage.
DOINT23CR10007
9. Remove the big O-ring.
DOINT23CR11021
10. Before remove the oil pump, mark 2 point

on top the oil pump by using permanent ink
pen. The marked point is for easier during
re-installation.
DOINT23CR11022
11. Remove the oil pump bolts.
DOINT23CR10008

TRANSMISSION / 13
12. Using special tool Mot. 1335, lift out the

pump and remove the belle-ville washer.
DOINT23CR10009
13. To remove the primary nut, ensure to do a

mark on it permanently. Use socket size of
46 mm (1.81 in), use high spec of an air im-
pact wrench due to remove the large size of
primary nut .
DOINT23CR10010

/ 14 TRANSMISSION
14. Pinch out the seal of the primary ball bearing

using a small screw driver.
DOINT23CR10011
15. Use the special tool MB991202 and

MD998348 to lift out the primary ball bear-
ing.
DOINT23CR11023
16. Remove the oil pan bolts.
DOINT23CR10014
17. Remove the oil pan and gasket.
DOINT23CR11033

TRANSMISSION / 15
18. Remove the oil filter and O-ring.
DOINT23CR11034
19. Remove the position switch cpl bolt and dis-

connect the position switch cpl connector.
DOINT23CR10015

/ 16 TRANSMISSION
20. Remove the cpl valve body bolts and push

the cpl valve body bracket until end to re-
move another bolts.
DOINT23CR10016
21. Remove the cpl valve body and disconnect

the cpl valve body connectors.
DOINT23CR11035
22. Remove the secondary cover countersunk

head screw (torx).
DOINT23CR10017

TRANSMISSION / 17
23. Remove the secondary cover and O-ring sec-

ondary cover.
DOINT23CR10018
24. Use plier remove the main connector clip.
DOINT23CR10019
25. Remove the Input speed sensor.
DOINT23CR10020
26. Remove the output speed sensor bracket.
DOINT23CR10021

/ 18 TRANSMISSION
27. Use plier remove the output speed sensor.
DOINT23CR10022
28. Press the main connector with finger and

remove the main connector and internal
cable harness.
CAUTION
Do not allowed to use any tool to take out
the main connector and internal cable har-
ness.
DOINT23CR11036
REASSEMBLY SERVICE POINTS

WTC23CSHAUL003
1. Put special tool P480129 on the input shaft

and slide a new oil seal.
DOINT23CR11001

TRANSMISSION / 19
2. Place the special tool P480130 on input shaft,

and knock by rubber hammer.
DOINT23CR11002
3. Slide a new oil seal to the special tool

P480125.
DOINT23CR11003
4. Place special tool P480125 with oil seal on

the selector shaft and knock in the oil seal
until no further possible.
DOINT23CR11004
5. Install the shift lever.

CAUTION
Ensure the shift lever is install to the correct
position, fix only one position as shown in
the illustration.
DOINT23CR10004

/ 20 TRANSMISSION
6. Tighten the self locking nut.

Specified torque:
1.45 kgm (14.5 Nm, 10.49 ft.lbs) ± 0.15 kgm
(1.5 Nm, 1.08 ft.lbs)
DOINT23CR10003
7. Ensure the oil ring connector is seat at it po-

sition as shown in the illustration.
DOINT23CR11037
8. Properly install the main connector and in-

ternal cable harness .
CAUTION
Ensure the connector slot lock at transmis-
sion case.
DOINT23CR11005

TRANSMISSION / 21
9. Install the main connector clip properly.
DOINT23CR11006
10. Lay-out the input speed sensor harness con-

nector to it position as shown in the illustra-
tion.
DOINT23CR11007
11. Slot in the output speed sensor bracket

properly as shown in the illustration.
DOINT23CR11008
12. Tighten the output speed sensor bracket

bolt.
Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.095 kgm
(0.95 Nm, 0.69 ft.lbs)
DOINT23CR10021

/ 22 TRANSMISSION
13. Connect all the connectors at the cpl valve

body.
DOINT23CR11009
14. Install the valve body and fit the special tool
P480142.
CAUTION
Make sure that the valve body metal slide
is fitted in the pin of the rooster cam plate.
DOINT23CR11039

TRANSMISSION / 23
15. Install the valve body bolts and tighten the

bolts.
Remove the special tool P480142.
CAUTION
Torque the bolts in order number as shown
Specified torque:
0.72 ft.lbs)
DOINT23CR11038
16. Connect the position switch connector to the

main cable harness and lock it by pushing
the gray button.
CAUTION
Ensure the harness connector is properly
locked.
DOINT23CR11042

/ 24 TRANSMISSION
17. Place position switch to the metal slide, with

the guiding pin on the back of the position
switch locked in the metal slide groove.
Align the position switch so the screw holes
lign-up, tighten the position switch bolts.
Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.095 kgm
(0.95 Nm, 0.69 ft.lbs)
DOINT23CR11012
18. Fix the oil filter with new O-ring.
DOINT23CR11034
19. Install the oil pan with gasket and magnet.
DOINT23CR11033

TRANSMISSION / 25
20. Tighten the oil pan bolts.

Specified torque:
0.72 ft.lbs)
CAUTION
DOINT23CR11043
21. Install the secondary cover with the new O-

ring.
DOINT23CR10018
22. Tighten the countersunk head screw (torx

type).
Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.095 kgm
(0.95 Nm, 0.69 ft.lbs)
CAUTION
DOINT23CR11041

/ 26 TRANSMISSION
23. Install the input speed sensor and tighten

the bolt.
Specified torque:
0.85 kgm (8.5 Nm, 6.15 ft.lbs) ± 0.2 kgm (2
Nm, 1.45 ft.lbs)
DOINT23CR10020
24. Use the special tools P480137 and MB998350

to install the primary ball bearing.
DOINT23CR11024
25. Use an air impact wrench to tighten the

primary nut.
Specified torque:
19.75 kgm (197.5 Nm, 142.85 ft.lbs) ± 1.75
kgm (17.5 Nm, 12.66 ft.lbs)
DOINT23CR11014
26. Install the belle-ville washer as shown in the

illustration.
DOINT23CR11015

TRANSMISSION / 27
27. Install the oil pump properly.

CAUTION
Ensure the oil pump oil-ring not protrude.
DOINT23CR11016
28. Tighten the oil pump bolts.

Specified torque:
0.72 ft.lbs)
CAUTION
DOINT23CR11040
29. Install new big O-ring to the transmission

case properly.
DOINT23CR11026

/ 28 TRANSMISSION
30. Clean the primary cover and fix it the trans-

mission housing.
DOINT23CR11017
31. Tighten the primary cover bolts with clamp.

Specified torque:
0.95 kgm (9.5 Nm, 6.87 ft.lbs) ± 0.25 kgm (2.5
Nm, 1.81 ft.lbs)
DOINT23CR10006

TRANSMISSION / 29
32. Replace with a new oil seal differential

(RH/LH) sides and put it in the housing, place
the special tool P480143 on the seal and use
a rubber hammer to knock oil seal into the
transmission housing.
DOINT23CR11028

/ 30 TRANSMISSION
NOTE

CVT Model YR 2011 English Edition RDCE-11PNCH080-00 July 2011 Printed in Malaysia
WORKSHOP MANUAL
BODY REPAIR
CR
Model YR 2012
Destination: ALL
Copyright ©
Perusahaan Otomobil
Nasional Sdn. Bhd.
WORKSHOP MANUAL ALL
Group Index /I
00 GENERAL ................................................................................... 00/1 - 00/25

1 BODY CONSTRUCTION ................................................................... 1/1 - 1/38
2 BODY DIMENSION AND MEASUREMENT METHOD ......................... 2/1 - 2/30
3 WELDED PANEL REPLACEMENT ...................................................... 3/1 - 3/46
4 CORROSION PROTECTION .............................................................. 4/1 - 4/25
5 SYNTHETIC RESIN PARTS ................................................................ 5/1 - 5/12
6 BODY COLOUR ................................................................................ 6/1 - 6/4

ALL WORKSHOP MANUAL
/ II Group Index
NOTE

GENERAL 00
Content /1
00 GENERAL
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ...................................... 00/2
CAUTION ............................................................................. 00/2
MANUAL DESCRIPTION .............................................................. 00/2

CONTENTS ............................................................................ 00/2
TEXT ................................................................................... 00/2
PAGE NUMBERS ..................................................................... 00/2
SECTIONS TITLES .................................................................... 00/2
DESTINATION ........................................................................ 00/2
BODY REPAIR .......................................................................... 00/4

STANDARD BODY REPAIR OPERATIONS ........................................ 00/4
STANDARD OPERATIONS FOR WELDED PANEL REPLACEMENT ........... 00/4
MAJOR SPECIFICATIONS ............................................................. 00/14

7 SEATER .............................................................................. 00/14
VEHICLE IDENTIFICATION ............................................................ 00/15

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/15
Code Plate Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/15
MODELS ............................................................................... 00/16
7 SEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/16
MODEL CODE ........................................................................ 00/16
CHASSIS NUMBER ................................................................... 00/16
Location 1 (under driver seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/17
Location 2 (under 2nd row seat, right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/17
ENGINE MODEL AND SERIAL NUMBER ......................................... 00/18
TRANSMISSION MODEL AND SERIAL NUMBER ............................... 00/18
Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/18
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/19
TENSIONER ...........................................................................
SEAT BELT WITH PRE-TENSIONER ................................................ 00/21
THEFT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/22
LOCATIONS ........................................................................... 00/23
TOP MARK ENGRAVING AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00/23

00 GENERAL
/2 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) WBR000FWORD11001
CAUTION
1. Improper service or maintenance of any of the SRS components or any of the SRS-related compon-
ents can lead to personal injury or death to the service personnel (from inadvertent firing of the
air bag) or to the driver and passenger (from rendering the SRS inoperative).
2. The SRS components and seat belt with pre-tensioner should not be subjected to heat. Please re-
move the SRS-ECU, Driver’s and Front Passenger’s Air Bag Modules, Clock Spring, Side-Airbag
Modules, Curtain Air Bag Modules, Front and Side Impact Sensors and Seat Belt Pre-Tensioners
before drying or baking the vehicle after painting.
• SRS-ECU, Air Bag Modules, Clock Spring, Impact Sensors: 93° C or more
• Seat belt with Pre-Tensioner: 90°C or more
3. Service or maintenance of any of the SRS components or any of the SRS-related components must
be performed only at an authorized MITSUBISHI dealer.
4. MITSUBISHI dealer personnel must thoroughly review the workshop manual, especially GROUP
52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any
of the SRS components or any of the SRS-related components.
MANUAL DESCRIPTION WBR000HUSEM11001
CONTENTS
The first page of this manual contains a table of content which lists the title and number of each
group.
TEXT
The vehicles to which the information in the text pertains are generally designated according to their
body classification. In some cases, other limiting designations such as name, type of drive system, etc.,
are given. If there are no such limiting designations, the information can be assumed to cover all
models.
PAGE NUMBERS
All pages are numbered consecutively within each group. The page numbers can be found on the
upper left or right of each page.
SECTIONS TITLES
The section titles can be found at the upper centre of each page.
DESTINATION
The destination to which the vehicle information in the text pertains are generally designated for
export market with Right Hand Drive (RHD) classification.

GENERAL 00
MANUAL DESCRIPTION /3
DOIAB000R02001

00 GENERAL
/4 BODY REPAIR
SYMBOL DESCRIPTION
E Component Diagram
parts.
F Part of componant
G Table for graphic explaination
BODY REPAIR WBR000BRSOP11001
STANDARD BODY REPAIR OPERATIONS

This group gives an explanation of the standard body repair operations for monochrome body and
vehicles with frame. For brief explanation on repair procedures concerning the frame in vehicles with
frame, please refer the following pages. Also, for panel replacement procedures for each vehicle,
refer to the respective Body Repair Manual of the individual vehicle model.
STANDARD OPERATIONS FOR WELDED
PANEL REPLACEMENT
In order to maintain the proper levels of
strength, rigidity and precision when carrying
out welded panel replacement, it is essential to
first gain a thorough understanding of the body
structure, and then to carry out all repair opera-
tions carefully and correctly. In addition, when
carrying out these operations, be sure to use the
proper protective equipment for each operation.
1. Rough cutting of panels
First make a rough cutting of portion of the
panel to be replaced, and then remove that
portion in order to make it easier to break
the spot welds.
CAUTION
• Select an appropriate location for the
cutting operation, and carry out the
work carefully so as not to cut into
places such as reinforcements located
inside the pillars or panels which are not
to be replaced.
DOIAB000R02002
• There are harnesses and hoses routed
inside the front pillar, rear pillar, fender
shield, side sill, etc. Carry out repair work
only after such items have been re-
moved.
• For overlap cutting allow an overlap of
approximately 30-50 mm (1.18-1.97 in)
when carrying out the cutting operation.

GENERAL 00
BODY REPAIR /5
2. Removal of the paint from spot-welded

point
In order to clearly identify the spot-welded
points, remove the coat of paint from areas
where it is difficult to determine the spot
welds.
DOIAB000R02003
3. Separation of spot-welded point

In order to carry out cutting and separation
of the spot-welded point, use a spot weld
cutter which is larger than the size of the
nugget, and make a hole only in the panels
to be replace.
When breaking spot-welded points in places
where the surrounding panels or other parts
interfere with the spot weld cutter, or if the
operation is hampered by a lack of space,
bend back the flanges in order to make it
easier to break the welds.
DOIAB000R02004
NOTE
If a replacement panel is to be mounted by
making plug welds from the side of the
panel remaining on the body, either a hole
can be made right through both the panel
which is to remain on the body and the
panel to be replaced.
4. Separation of brazing or arc welds
Use a pneumatic grinder or similar tool to
cut the brazed or arc welded portion (such
as the upper sections of pillars), be careful
not to damage the panel that is not to be
replaced.
DOIAB000R02005

00 GENERAL
/6 BODY REPAIR
5. Spot weld finishing

Use a pneumatic grinder or similar tool to
grind and smooth any weld traces which
might be left on the body, be careful not to
damage any of the panels which are not to
be replaced. Be sure to wear safety goggles
when carrying out this operation.
DOIAB000R02006
6. Flange repair for spot weld traces

Repair any flanges which become bent or
deformed when spot welds are broken or
during the course of any other work.
DOIAB000R02007
7. Making holes in new parts for MIG plug

welding
Make holes approximately 5-6 mm (0.2-0.24
in) diameter at points where MIG plug welds
are to be made because spot welding is not
possible.
DOIAB000R02013

GENERAL 00
BODY REPAIR /7
DOIAB000R02014
8. Removal of paint coat from new parts and

from the vehicle body
Use a polishing wheel or similar tool to re-
move the paint coat from both sides of the
new part and the body in order to provide
for the proper flow of current when spot
welding.
CAUTION
Do not use a flame for paint coat removal,
because doing so might damage the paint
coat on panels which are not to be replaced,
which will result in corrosion.
DOIAB000R02015
9. Rough cutting of new parts

Cut off the unnecessary sections of new
parts. Allow an overlap of approximately 30-
50 mm (1.18-1.97 in) when carrying out
overlap cutting of the pillars, side sills and
other locations.
DOIAB000R02016
10. Overlap cutting of new parts

For locations in which butt-welding is to be
carried out, first temporarily attach the new
parts to the body, and then cut the two
panels simultaneously.
Item Description
A Edge of new parts
B Edge of panel on panel body
CAUTION
Be careful not to cut the reinforcements or
DOIAB000R02017
panels which are not to be separated and

00 GENERAL
/8 BODY REPAIR
which are located inside the pillars and other

components.
NOTE
If a reinforcement or panel which is not to
be replaced is cut accidentally, first repair
the mistake by welding before proceeding
with the rest of the work.
11. Cutting of new parts using a measurement
marking
If overlap cutting is not possible in a place
where butt-welding is to be carried out,
make a measurement marking on the new
part at the exact same measurement which
was used for cutting the body panel, and
then cut the new part using this measure-
ment marking.
• Two-layer construction
When cutting a front pillar or center pillar
which has a two-layer construction with no
DOIAB000R02008 reinforcement, cut the inner panel and outer
panel approximately 50 mm (1.97 in) apart
in order to obtain maximum strength.
Item Description
A Inner panel
B Outer panel
• Three-layer construction
When cutting a front pillar or center pillar
which has a three-layer construction (double-
box construction) which includes an inner
panel, outer panel and reinforcement at the
same position, do not forget to butt-weld
the reinforcement. Cut the inner panel in
two places in order to provide ample work-
ing space for butt-welding the reinforce-
ment.
Item Description
DOIAB000R02009 A Inner panel cutting line
B Outer panel and reinformation
cutting line
C Inner panel
CAUTION
Carry out the cutting operations carefully so
that the cut ends fit together properly.

GENERAL 00
BODY REPAIR /9
12. Application of spot sealer to spot-welded

parts
Apply an electro-conductive spot sealer to
the connecting surface of both the new parts
and the vehicle body in order to provide
corrosion protection.
DOIAB000R02010
13. Temporary mounting of new parts

• In order to bring the new parts into the
proper mounting position, measure each
part carefully and make any corrections
necessary in order to obtain agreement
with the measurements.
DOIAB000R02011
• After adjustment to the standard dimen-

sions, make temporary welds for the new
parts and then check to be sure that the
closing and fit of the doors, fenders and
lid are correct.
In addition, for parts which should be
symmetrical to the body centre, check to
be sure that the distances from the body
centre point to the right and left parts
are the same.
CAUTION
During temporary mounting, it is extremely
DOIAB000R02012
important to obtain accurate measurements
for each part. The mounting positions for
the front and rear suspensions are especially
crucial with regard to safety and for the
purpose of wheel alignment, so they must
be mounted correctly.

00 GENERAL
/ 10 BODY REPAIR
14. Butt welding

For butt welding, make provisional MIG spot
welds at intervals of 10-15 mm (0.39-0.59 in),
and then complete the welding by making
welds at the specified intervals, alternate
positions in order to prevent warping being
caused by the welding heat.
DOIAB000R02018
CAUTION
Weld completely so that there are no pin-
holes.
DOIAB000R02019
15. Spot welding

When carrying out spot welding, position
the electrode tips correctly, and also hold the
two panels securely together with vise-grip
pliers after making sure that the panels are
in perfect contact with each other.
• Make sure that the application of force
is sufficiently maintained by the arm.
• Use a test piece to check the second cur-
rent and the current application time of
the spot welder, and adjust the values as
appropriate.
DOIAB000R02020
16. Plug welding

If spot welding is not possible, make holes
in the new parts for plug welding and then
carry out MIG welding. If this type of welding
is used, the strength of the welds will vary if
the holes are too small or too big, so make
holes with a diameter of 5-6 mm (0.2-0.24
in). In addition, hold the two panels securely
together by using vise-grip pliers to make
sure that they are in perfect contact with
each other.
DOIAB000R02021

GENERAL 00
BODY REPAIR / 11
NOTE
Depending on the working conditions, it
might also be possible to make holes in the
panel remaining on the body.
17. Hemming
If hemming is to be carried out at the rear
wheel cutting line, or at the door outer
panels or other parts, use a hammer and
dolly or hemming tool to do the work
manually.
Item Description
A Hemming
DOIAB000R02022
DOIAB000R02023
• After completion of hemming, make MIG

spot welds at 50-60 mm (1.97-2.36 in) in-
tervals at the joint between the folded
panel and the mating panel.
DOIAB000R02024

00 GENERAL
/ 12 BODY REPAIR
18. Finishing for butt welding and plug welding

Do the finishing to smooth the protruding
weld traces. However, the butt-welded joints
of reinforcements and other internal parts
will be stronger if the weld traces are not
ground down.
CAUTION
• Be careful not to grid the panel down
too much
• Before welding the outer panel, be sure
to apply anticorrosion agent to the weld
locations on the inside reinforcements
DOIAB000R02025
19. Soldering of butt-welded joints

After the finishing for the butt welds has
been completed, carry out the soldering. If
applying solder in areas where the rigidity
of the outer panel is low, the heat of the
burner may cause the panel to warp. There-
fore, carry out embossing repairs using a
hammer and a dolly to limit the amount of
soldering as much as possible.
CAUTION
Because solder-finishing work generates
toxic gases and dust, be sure to carry out
DOIAB000R02026
the operation in a place which is equipped
with a dust collector, and be sure to wear
protective gear.
20. Application of body sealant
Apply an ample amount of body sealant so
that there are no gaps, in accordance with
the “Body Sealing Locations” section of the
respective “Body Repair Manual” for the in-
dividual vehicle model.
NOTE
After sealant has been applied to any extern-
al surface, make it smooth in order to main-
tain a good external appearance.
DOIAB000R02027

GENERAL 00
BODY REPAIR / 13
21. Application of anticorrosion agent

Apply a sample amount of anticorrosion
agent to any welded areas and to all surface
from which the paint coat was removed.
Heat may cause damage to paint coat welded
areas
, so be sure to apply the anticorrosion agent
to both the inner and outer surface of the
panel.
Use an aerosol-type anticorrosion agent for
application to the side sills, pillars and other
similar parts which have a following construc-
DOIAB000R02028 tion, by utilizing the trim mounting holes,
etc.
CAUTION
Wipe off any anticorrosion agent which
oozes out onto the surface to be painted
later. The presence of such anticorrosion
agent will prevent correct application of the
paint coat.
DOIAB000R02029
22. Application of undercoat

If the underbody has been repaired or re-
placed, carefully apply under coat as de-
scribed in the respective “Body Repair
Manual” for the individual vehicle model.
DOIAB000R02030

00 GENERAL
/ 14 MAJOR SPECIFICATIONS
MAJOR SPECIFICATIONS WBR000MSPEC12001
7 SEATER
DOINC000R09003
Items / Model FZ6YNSXRMA0 FZ6YNJXRMA0 FZ6YRJXRMA0 FZ6YRHXRMA0

Overall length 1 4592 mm (180.79 in)
Overall width 2 1809 mm (71.22 in)
Overall height 3 1691 mm (66.57 in)
Wheelbase 4 2730 mm (107.48 in)
Front track 5 1542 mm (60.71 in)
Rear track 6 1530 mm (60.24 in)
Minimum running
ground clearance 7 155 mm (6.1 in) (Subframe front center)
(Unladen)
Front overhang 8 911 mm (35.87 in)
Rear overhang 9 951 mm (37.44 in)
Weight : 1390 kg (13900 1417 kg (14170 1437 kg (14370 1450 kg (14500
Kerb weight N, 3064.95 lbs) N, 3124.48 lbs) N, 3168.58 lbs) N, 3197.25 lbs)
Gross vehicle weight 1916 kg (19160 1943 kg (19430 1963 kg (19630 1976 kg (19760
N, 4224.78 lbs) N, 4284.32 lbs) N, 4328.42 lbs) N, 4357.08 lbs)
Max. axle weight

GENERAL 00
Items / Model FZ6YNSXRMA0 FZ6YNJXRMA0 FZ6YRJXRMA0 FZ6YRHXRMA0

Front 950 kg (9500 N, 2094.75 lbs)
Rear 1150 kg (11500 N, 2535.75 lbs)
Seating capacity 7
Engine S4PH -1-CPM S4PH -1-CPM S4PH -1-CPA S4PH -1-CPA
Model No. 1597 cm³ (97.45 1597 cm³ (97.45 1597 cm³ (97.45 1597 cm³ (97.45
Total displacement cu.in) cu.in) cu.in) cu.in)
Transmission
Model F5M42 F5M42 F4A4B F4A4B
Type 5 – Speed 5 – Speed 4 – Speed Auto- 4 – Speed Auto-
Manual transmis- Manual trans- matic transmis- matic transmis-
sion mission sion sion
Fuel supply system Electronic controlled multipoint fuel injection
VEHICLE IDENTIFICATION
WBR000VIDEN12001

Location
The vehicle information code plate is riveted on
the center pillar RH (driver side).
DOINC000R09004
Code Plate Description

The vehicle information code describe the model
code, engine model, transmission model, colour
code, etc.
Symbol Description
A VIN CODE
B ENGINE
C TRANS AXLE
D EXTERIOR CODE
E INTERIOR CODE
DOIKC000R03005
F OPTION CODE
G GROSS VEHICLE WEIGHT
H GROSS COMBINATION WEIGHT
I FRONT AXLE WEIGHT
J REAR AXLE WEIGHT

00 GENERAL
MODELS
7 SEATER
Model code Engine model Transmission model Fuel supply system
S4PH -1- CPM 1597 cm³
YNSXRMA0 F5M42 (2WD - 5-Speed M/T)
(97.45 cu.in)
S4PH -1- CPM 1597 cm³
YNJXRMA0 F5M42 (2WD - 5-Speed M/T)
(97.45 cu.in)
FZ6 MPI
S4PH -1- CPA 1597 cm³ F4A4B (2WD - 4-Speed AT)
YRJXRMA0
(97.45 cu.in)
S4PH -1- CPA 1597 cm³ F4A4B (2WD - 4-Speed AT)
YRHXRMA0
(97.45 cu.in)
MODEL CODE
1 2 3 4 5 6 7 8 9 10 11
↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
F Z 6 Y N S X R M A 0
No. Items Contents

1 Car segment F : MPV
2 Platform Z : S7
3 Engine size 6 : S4PH DOCH (1597 cm³ (97.45 cu.in))
4 Body type Y : S7 (7 Seater)
5 Transmission type
R : 4 – Speed Automatic Transmission
S : Low Line
H : H - Line
7 Engine type X : MPI DOHC + CPS
R : Right hand drive
L : Left hand drive
CHASSIS NUMBER
The chassis number is engraved at two location.

GENERAL 00
Location 1 (under driver seat)

The chassis number is engraved on the front floor
crossmember under driver seat. The chassis
number can be seen once floor carpet is opened.
NOTE:
DOINC000R09006
Location 2 (under 2nd row seat, right side)

The chassis number is engraved on the rear floor
at 2nd row seat, right side. The chassis number
can be seen direct on the floor carpet once the
second seat is tumble.
DOINC000R09005
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
P L 1 F Z 6 Y N R 8 F X X X X X X
No. Items Contents

1–3 WMI Malaysia
4 Size F MPV
5 Model Series Z S7
6 1597 cm³ (97.45 cu.in) petrol en-
6 Engine Displacement
gine
7 Body Type Y S7 ( 7seater)
N 5 – Speed Manual transmission
8 Transmission type
R 4 – Speed Automatic transmission
R Right hand drive
L Left hand drive
8 2008
10 Production Year 9 2009
A 2010
11 Manufacturer. Plant F MVF Shah Alam
12–17 Chassis Number — 000001

00 GENERAL
ENGINE MODEL AND SERIAL NUMBER

cylinder block.

S4PH 1597 cm³ (97.45 cu.in)
Symbol Description
A Engine model number
B Engine serial number
the engine model.
Engine Serial Number [Example]

NS0001
NOTE:
DOINC000R09001
TRANSMISSION MODEL AND SERIAL

NUMBER
Manual transmission
The transmission model and serial number en-
graving on the transmission case as shown in the
illustration.
Symbol Description
NOTE:
DOIMC000L08009

GENERAL 00
Automatic transmission
The transmission model and serial number, en-
graving on the transmission case.
Symbol Description
NOTE:
DOIIT23AR08151

00 GENERAL
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER
DOINC000R09007
Symbol Description
A Clock spring
B Front driver's air bag module
C Air Bag Control Unit
D Front driver's air bag
E Front passenger's air bag
(1)
F Seat belt with pre-tensioner

G Front passenger airbag module
(1)
NOTE:
(1) If fitted
To improve safety, the SRS and seat belts with
pretensioner are available. These systems en-
hance collision safety by restraining the front
passengers in case of an accident. The frontal air
bags (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 air bag modules, SRS air
bag control unit, SRS air bag warning lamp, clock
spring and pre-tensioners. The air bags are loc-

GENERAL 00
ated in the center of the steering wheel and

above the glove box. Each air bag has a folded
bag and an inflator unit. The air bag 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 be-
fore starting any such work. Extreme care must
be given when servicing the SRS to avoid injury
to the service personnel (by inadvertent deploy-
ment of the air bags or inadvertent operation
of the seat belt with pretensioner) or the driver
(by rendering the SRS or the seat belt with pre-
tensioner inoperative).
SEAT BELT WITH PRE-TENSIONER
The seat belts with pre-tensioners are installed
on both center pillars.
The pre-tensioner, which is controlled by the SRS-
ECU, works simultaneously with the SRS air bag
in a head-on collision. When triggered, the SRS-
ECU sends a squib igniting signal to the gas
generator. Generated gas moves the rotor to
take up seat belt slack. This prevents a passenger
from moving forwards excessively. After this, the
ELR works to inhibit the seat belt.
CAUTION
Never disassemble or give an impact to the seat
belt with pre-tensioner.
Symbol Description
1 Sash guide cover and upper
bolt
2 Pre-tensioner connector discon-
nection
3 Seat belt with pre-tensioner
DOINC52BR09093

00 GENERAL

WBR000VIDEN12002
THEFT PROTECTION
PROTON GENUINE PARTS LOGO
DOINB000R09008
In order to protect against theft, a Top mark of

Proton Genuine Logo is attached as engraving
to the following major parts of the engine and
transaxle, as well as main outer panels. Engine
cylinder block, Transaxle housing, Front End
Module (FEM), Fender, Hood, Doors and Tailgate.
In addition, a theft-protection engraving is at-
tached to replacement parts for the body outer
panel main components and the same data is
stamped into replacement parts for engine and
the transaxle.
CAUTION
DOINW002R09001
Cautions regarding panel repairs:
(1) When repainting original parts, do so after
first masking the theft-protection mark.
After painting, be sure to peel off the
masking tape.
(2) The theft-protection mark for replacement
parts is covered by masking tape, so such
parts can be painted as is. The masking tape
should be removed after painting is finished.
(3) The theft-protection mark should not be re-
moved from original parts or replacement
parts.

GENERAL 00
LOCATIONS
TOP MARK ENGRAVING AREA
Front End Module (FEM) Fender
DOINB000R09018 DOINB000R09017

00 GENERAL
Front door Rear door

GENERAL 00
Tailgate Hood

00 GENERAL
NOTE

BODY CONSTRUCTION 1
Content /1
1 BODY CONSTRUCTION
BODY COMPONENTS ................................................................. 1/2
BODY CONSTRUCTION CHARACTERISTICS ...................................... 1/7

MAINTENANCE, SERVICEABILITY ............................................... 1/7
SIDE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/7
BODY MAIN CROSS-SECTIONAL VIEWS ........................................ 1/8
FRONT BODY CONSTRUCTION ................................................... 1/17
FENDER SHIELD CONSTRUCTION ................................................ 1/19
FRONT DECK CONSTRUCTION .................................................... 1/21
UNDER BODY ........................................................................ 1/22
FRONT FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/22
REAR FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/23
SIDE BODY ........................................................................... 1/25
FRONT SIDE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/25
REAR SIDE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/26
REAR END PANEL ................................................................... 1/27
ROOF .................................................................................. 1/28
DOOR CONSTRUCTION ............................................................ 1/29
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/29
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/30
SILENCER APPLICATION .............................................................. 1/33

SILENCER APPLICATION LOCATIONS ............................................ 1/33
DOOR DAMPING SHEET ........................................................... 1/35
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/35
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/35
SOUND DAMPENING FOAM MATERIAL ........................................ 1/35
SOUND DAMPENING FOAM MATERIAL USAGE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 1/35

1 BODY CONSTRUCTION
/2 BODY COMPONENTS
BODY COMPONENTS WBR001BCONS11002
DOIQB001R11013

BODY CONSTRUCTION 1
BODY COMPONENTS /3
Body Components
1. Bracket assy wheel carrier mounting front 44. Cross member front floor lower
LH/RH 45. Member assy front floor front LH/RH
2. Plate assy FEM mounting LH/RH 46. Member front floor front lower LH/RH
3. Panel assy housing front spring LH/RH 47. Support assy instrument panel lower
4. Bracket assy wheel carrier mounting outer 48. Reinforcement assy backbone upper
LH/RH 49. Reinforcement backbone LH/RH
5. Reinforcement fender shield outer front LH/RH 50. Member assy front floor lower
6. Bracket assy fender side mounting LH/RH 51. Sill assy front floor side inner LH/RH
7. Bracket assy installation panel lower LH 52. Panel assy front floor LH/RH
8. Reinforcement wheel carrier mounting front 53. Reinforcement assy front seat belt lower
LH/RH 54. Reinforcement assy front seat front
9. Bracket assy hood release lever RHD 55. Patch assy backbone rear LH/RH
10. Panel assi front fender LH/RH 56. Panel assy backbone
11. Member assy front outer LH/RH 57. Member front floor front center
12. Support assy transmission 58. Member assy front floor rear LH/RH
13. Bracket assy support transmission 59. Hanger front muffler
14. Member assy front inner LH/RH 60. Reinforcement assy parking brake
15. Structure adhesive 61. Member assy backbone rear
16. Bulkhead assy support member front rear LH 62. Hood outer
17. Support battery tray outer 63. Reinforcement assy hood hinge LH/RH
18. Reinforcement assy support member front in- 64. Retainer assy rod hood support
ner LH/RH 65. Reinforcement assy hood lock
19. Patch support member outer LH/RH 66. Reinforcement hood lock outer
20. Reinforcement support engine inner front 67. Panel hood inner
21. Support engine mounting rear 68. Retainer wiper fit (LHD)
22. Bracket assy cowl top outer front 69. Retainer assy wiper shaft center
23. Support assy battery tray inner 70. Retainer wiper fit (RHD)
24. Bracket assy front garnish mounting LH/RH 71. Bracket assy wiper mounting side
25. Reinforcement fender shield inner front LH/RH 72. Cover assy cowl vent
26. Panel assy front pillar inner lower LH/RH 73. Bracket assy instrument panel
27. Bracket assy fuse box 74. Retainer wiper shaft side LH/RH
28. Gusset assy brace support member front LH/RH 75. Reinforcement cowl side inner LH/RH
29. Support assy engine inner 76. Bulkhead cowl top inner center
30. Bracket assy wheel carrier mounting rear 77. Reinforcement cowl top inner
LH/RH 78. Reinforcement steering column LH(LHD) /
31. Reinforcement assy fender side mounting RH(RHD)
32. Brace assy support member front LH/RH 79. Bracket assy HVAC unti upper
33. Bracket brake hose LH/RH 80. Panel assy cowl top inner (LHD/RHD)
34. Reinforcement brace support member LH/RH 81. Reinforcement rail roof side LH/RH
35. Bracket assy front spring LH/RH 82. Rail roof front
36. Bracket assy instrument panel side mounting 83. Panel roof
upper 84. Rail roof middle
37. Bracket assu support transmission mounting 85. Rail roof rear
38. Reinforcement support transmission 5MT
39. Nut (12) x 4
40. Holder nut x 4
41. Reinforcement wheel carrier mounting rear
42. Reinforcement cross member A-pillar side in-
ner RH (RHD)
43. Member front floor upper

1 BODY CONSTRUCTION
/4 BODY COMPONENTS
Continued WBR001BCONS11003
DOIQB001R11014

BODY CONSTRUCTION 1
BODY COMPONENTS /5
Body Components
1. Reinforcement assy front door side impact 41. Panel assy side outer LH/RH
LH/RH 42. Bracket assy fender mounting lower LH/RH
2. Bracket box pull handle 43. Bracket assy fender mounting
3. Panel front door outer LH/RH 44. Reinforcement assy door striker
4. Panel front door inner LH/RH 45. Bracket assy fender mounting
5. Patch assy door hinge LH/RH 46. Reinforcement rear pillar LH/RH
6. Reinforcement front door belt line inner LH/RH 47. Extension rear end lower LH
7. Reinforcement front door door latch LH/RH 48. Hook rear seat A LH/RH
8. Reinforcement front door belt line outer 49. Reinforcement assy parcel sheft side LH/RH
LH/RH 50. Reinforcement side sill inner LH/RH
9. Sash assy front door window LH/RH 51. Panel assy quarter inner upper LH/RH
10. Panel rear door outer LH/RH 52. Brace rear shelf LH/RH
11. Bracket box pull handle 53. Housing rear combi lamp LH/RH
12. Panel rear door inner LH/RH 54. Panel rear wheel house outer LH/RH
13. Reinforcement assy rear door side impact 55. Housing assy rear combi lower lamp LH/RH
LH/RH 56. Reinforcement trunk lid drain channel LH/RH
14. Bracket glass rear door LH/RH 57. Housing rear combi upper lamp LH/RH
15. Patch assy door hinge LH/RH 58. Reinforcement striker LH/RH
16. Reinforcement rear door belt line inner LH/RH 59. Pillar assy rear inner LH/RH
17. Reinforcement rear door belt line outer LH/RH 60. Bracket assy fuel filler neck
18. Reinforcement rear door latch LH/RH 61. Bracket assy fuel filler neck (NGV)
19. Sash assy rear door window LH/RH 62. Sill rear floor side inner LH/RH
20. Extension side sill front LH/RH 63. Extension rear floor front upper
21. Bracket assy FEM adapter LH/RH 64. Reinforcement assy rear floor seat mounting
22. Reinforcement assy fender shield outer rear LH/RH
LH/RH 65. Reinforcement assy NGV tank bracket mount-
23. Reinforcement assy front pillar inner lower ing LH/RH
LH/RH 66. Extension assy rear floor front lower
24. Bulkhead side sill outer LH/RH 67. Reinforcement rear floor side member front
25. Reinforcement side sill outer front LH/RH LH/RH
26. Bracket assy 1st row seat belt retractor LH/RH 68. Bulkhead extension rear floor front LH/RH
27. Reinforcement assy front door check arm 69. Bracket assy fuel tank front LH/RH
LH/RH 70. Side member assy rear floor LH/RH
28. Pillar assy upper belt reinforcement LH/RH 71. Reinforcement assy rear floor side member
29. Reinforcement assy upper hinge front LH/RH front center LH/RH
30. Reinforcement side sill outer front LH/RH 72. Bracket assy splash shield LH/RH
31. Bulkhead center pillar inner 1 73. Reinforcement assy rear seat front hinge LH/RH
32. Panel assy front pillar inner upper LH/RH 74. Reinforcement assy rear seat mounting center
33. Reinforcement assy front pillar upper LH/RH 75. Bracket spare tyre assy
34. Bulkhead center pillar inner 2 76. Hanger assy rear muffler front
35. Panel assy front pillar front inner upper 77. Extension brace rear wheel house LH/RH
36. Reinforcement assy center pillar outer LH/RH 78. Bracket assy brake hose LH/RH
37. Panel assy center pillar inner LH/RH 79. Extension cross member rear floor side LH/RH
38. Reinforcement side sill extension LH/RH 80. Cross member rear floor
39. Reinforcement assy door striker
40. Rail assy roof side inner LH/RH

1 BODY CONSTRUCTION
/6 BODY COMPONENTS
Body Components
81. Reinforcement assy rear wheel house inner 101. Reinforcement assy trunk lid striker
LH/RH 102. Panel assy rear end outer
82. Reinforcement assy rear floor side member 103. Reinforcement assy rear seat striker
rear center LH/RH 104. Reinforcement rear shelf front
83. Reinforcement spring house rear LH/RH 105. Brace assy retractor center
84. Hanger assy rear muffler rear LH 106. Reinforcement assy child restraint
85. Bracket fuel tank rear LH/RH 107. Hook rear seat A
86. Hook shipping 108. Panel rear shelf
87. Hanger assy rear muffler rear RH 109. Reinforcement rear shelf rear
88. Extension rear floor side member LH/RH 110. Hinge assy trunk lid LH
89. Brace rear wheel house outer LH/RH 111. Hinge assy trunk lid RH
90. Reinforcement assy rear floor side member 112. Torsion bar trunk lid LH
rear 113. Torsion bar trunk lid RH
91. Plate assy ventilation plug 114. Panel trunk lid inner
92. Reinforcement assy side member rear floor 115. Reinforcement assy trunk lid hinge LH/RH
rear 116. Reinforcement assy trunk lid latch
93. Reinforcement assy towing hook 117. Bracket RC lamp LH/RH
94. Bracket rear spring LH/RH 118. Bracket trunk lid garnish
95. Brace rear wheel house inner LH/RH 119. Panel trunk lid outer
96. Panel rear wheel house inner LH/RH
97. Panel assy rear floor
98. Panel assy rear floor (NGV)
99. Panel rear end inner
100. Bumpstop bracket LH/RH

BODY CONSTRUCTION 1
BODY CONSTRUCTION CHARACTERISTICS /7
BODY CONSTRUCTION CHARACTERISTICS WBR001BCONS11004
MAINTENANCE, SERVICEABILITY
SIDE STRUCTURE
DOIQB001R11018
The door opening section is provided with panel positioning notches and lipseam to improve work-
ability when replacing panels.
DOIQB001R11017 DOIQB001R11019
Notch Lipseam

1 BODY CONSTRUCTION
/8 BODY CONSTRUCTION CHARACTERISTICS
BODY MAIN CROSS-SECTIONAL VIEWS WBR001BCONS11005
DOIQB001R11045
DOIQB001R12002
Symbol Description
A Support member front inner LH/RH
B Support member front outer LH/RH

BODY CONSTRUCTION 1
BODY CONSTRUCTION CHARACTERISTICS /9
DOIQB001R12003
Symbol Description
A Reinforcement fender shield outer rear LH/RH
B Reinforcement fender shield outer front LH/RH
C Support member front inner LH/RH
D Member front outer LH/RH
E Reinforcement support member front inner LH/RH

1 BODY CONSTRUCTION
/ 10 BODY CONSTRUCTION CHARACTERISTICS
DOIQB001R11048
Symbol Description
A Panel cowl top inner
B Cross member dash lower center
C Panel dash
D Reinforcement cross member dash lower
E Cross member assy dash outer
DOIQB001R11034
Symbol Description
A Panel roof

BODY CONSTRUCTION 1
BODY CONSTRUCTION CHARACTERISTICS / 11
Symbol Description
B Panel side outer LH/RH
C Panel front pillar fornt inner upper LH/RH
D Reinforcement front pillar upper LH/RH
DOIQB001R11035
Symbol Description
A Reinforcement side sill outer
B Sill assy front floor side inner
C Panel assy front floor
D Reinforcement side sill outer front
DOIQB001R11036
Symbol Description
A Reinforcement front pillar upper LH/RH
B Reinforcement center pillar outer LH/RH
C Panel front pillar front inner upper LH/RH

1 BODY CONSTRUCTION
DOIQB001R11037
Symbol Description
A Panel roof
B Rail roof front
8
DOIQB001R11038
Symbol Description
A Reinforcement side sill outer LH/RH
B Panel front pillar inner upper LH/RH
C Reinforcement front pillar inner lower LH/RH

BODY CONSTRUCTION 1
DOIQB001R11046
DOIQB001R11039
Symbol Description
A Panel center pillar inner LH/RH
C B pillar upper belt reinforcement LH/RH
D Reinforcement center pillar outer LH/RH

1 BODY CONSTRUCTION
DOIQB001R11040
Symbol Description
A Panel center pillar inner LH/RH
C Reinforcement door striker
D Reinforcement center pillar inner LH/RH
11
DOIQB001R11041
Symbol Description
A Panel roof
B Rail roof rear
12

BODY CONSTRUCTION 1
DOIQB001R12004
Symbol Description
A Panel side outer LH/RH
B Panel assy quarter inner upper LH/RH
C Panel rear wheel house outer LH/RH
D Panel rear wheel house inner LH/RH
E Panel rear floor
F Extension brace rear wheel house LH/RH
G Side member rear floor LH/RH
DOIQB001R11043

1 BODY CONSTRUCTION
Symbol Description
A Reinforcement front pillar upper LH/RH
B Reinforcement rear pillar LH/RH
C Rail roof side inner LH/RH
DOIQB001R11044
Symbol Description
A Reinforcement trunk lid striker
B Panel rear end inner
C Panel rear end outer
D Panel rear floor

BODY CONSTRUCTION 1
FRONT BODY CONSTRUCTION WBR001BCONS11006
DOIQB001R11002

1 BODY CONSTRUCTION
Body components
1. Plate assy fem mounting LH 32. Support assy battery tray inner
2. Plate assy fem mounting RH 33. Bracker assy front garnish mounting LH
3. Bracket assy wheel carrier mounting outer LH 34. Bracket assy cowl top outer front
4. Bracket assy wheel carrier mounting outer RH 35. Reinforcement fender shield inner front LH
5. Bracket assy wheel carrier mounting front LH 36. Reinforcement fender shield inner front RH
6. Bracket assy wheel carrier mounting front RH 37. Bracket assy fuse box
7. Panel assy housing front spring LH 38. Pannel assy front pillar inner lower LH
8. Panel assy housing front spring RH 39. Pannel assy front pillar inner lower RH
9. Bracket assy fender side mounting LH 40. Gusset assy brace support member front LH
10. Bracket assy fender side mounting RH 41. Gusset assy brace support member front RH
11. Reinforcement wheel carrier mounting front 42. Bracket assy wheel carrier mounting rear LH
LH 43. Bracket assy wheel carrier mounting rear RH
12. Reinforcement wheel carrier mounting front 44. Reinforcement assy fender shield outer front
RH RH
13. Bracket assy installation panel lower LH 45. Support assy engine inner
14. Bracket assy hood release lever RHD 46. Bracket assy front spring LH
15. Reinforcement assy fender shield outer front 47. Bracket assy front spring RH
LH 48. Reinforcement brace support member LH
16. Member assy front outer LH 49. Reinforcement brace support member RH
17. Member assy front outer RH 50. Bracket assy IP side mounting upper
18. Bracket assy support transmission 51. Reinforcement assy fender side mounting
19. Support assy transmission 52. Brace assy support member front LH
20. Structure adhesive 53. Brace assy support member front RH
21. Reinforcement assy support member front in- 54. Bracket brake hose LH
ner LH 55. Bracket brake hose RH
22. Reinforcement assy support member front in- 56. Reinforcement support transmission 5MT
ner RH 57. Nut (12) x 4
23. Support battery tray outer 58. Holder nut x 4
24. Support engine mounting rear 59. Reinforcement wheelcarrier mounting rear
25. Bulkhead assy support member front rear LH 60. Reinforcement crossmember A-pillar side inner
26. Reinforcement support engine inner front RH (RHD)
27. Member assy front inner LH 61. Bracket assy support transmission mounting
28. Member assy front inner RH
29. Patch support member outer LH
30. Patch support member outer RH
31. Bracket assy front garnish mounting RH

BODY CONSTRUCTION 1
FENDER SHIELD CONSTRUCTION WBR001BCONS11007
DOIQB001R11026

1 BODY CONSTRUCTION
Body components
1. Plate assy fem mounting LH 22. Reinforcement assy support member front in-
2. Plate assy fem mounting RH ner RH
3. Bracket assy wheel carrier mounting outer LH 23. Support battery tray outer
4. Bracket assy wheel carrier mounting outer RH 24. Support engine mounting rear
5. Bracket assy wheel carrier mounting front LH 25. Bulkhead assy support member front rear LH
6. Bracket assy wheel carrier mounting front RH 26. Reinforcement support engine inner front
7. Panel assy housing front spring LH 27. Member assy front inner LH
8. Panel assy housing front spring RH 28. Member assy front inner RH
9. Bracket assy fender side mounting LH 29. Patch support member outer LH
10. Bracket assy fender side mounting RH 30. Patch support member outer RH
11. Reinforcement wheel carrier mounting front 31. Bracket assy front garnish mounting RH
LH 32. Support assy battery tray inner
12. Reinforcement wheel carrier mounting front 33. Bracket assy front garnish mounting LH
RH 34. Bracket assy cowl top outer front
13. Bracket assy installation panel lower LH 35. Reinforcement fender shield inner front LH
14. Bracket assy hood release lever RHD 36. Reinforcement fender shield inner front RH
15. Reinforcement assy fender shield outer front 37. Bracket assy fuse box
LH 38. Pannel assy front pillar inner lower LH
16. Member assy front outer LH 39. Pannel assy front pillar inner lower RH
17. Member assy front outer RH 40. Reinforcement assy fender shield outer front
18. Bracket assy support transmission RH
19. Support assy transmission 41. Panel assy front fender LH
20. Structure adhesive 42. Panel assy front fender RH
21. Reinforcement assy support member front in-
ner LH

BODY CONSTRUCTION 1
FRONT DECK CONSTRUCTION WBR001BCONS11008
DOIQB001R11008
Parts Name
1. Retainer wiper fit (LHD) 9. Reinforcement cowl side inner LH
2. Retainer assy wiper shaft center 10. Reinforcement cowl side inner RH
3. Retainer wiper fit (RHD) 11. Bulkhead cowl top inner center
4. Bracket assy wiper mounting side 12. Reinforcement cowl top inner
5. Bracket assy instrument panel 13. Reinforcement steering column LH (LHD)
6. Cover cowl vent 14. Reinforcement steering column RH
7. Retainer wiper shaft side LH 15. Bracket assy HVAC unit upper
8. Retainer wiper shaft side RH 16. Panel assy cowl top inner (RHD/LHD)

1 BODY CONSTRUCTION
UNDER BODY WBR001BCONS11009
FRONT FLOOR
DOIQB001R11009
Body Components
1. Member front floor upper LH 16. Reinforcement backbone LH
2. Member front floor upper RH 17. Reinforcement backbone RH
3. Crossmember front floor lower 18. Panel assy backbone
4. Member assy front floor front LH 19. Patch assy backbone rear LH
5. Member assy front floor front RH 20. Patch assy backbone rear RH
6. Support assy instrument panel lower 21. Member front floor front center
7. Member front floor front lower LH 22. Reinforcement assy front seat belt lower LH
8. Member front floor front lower RH 23. Reinforcement assy front seat belt lower RH
9. Panel assy backbone 24. Reinforcement assy front seat front LH
10. Sill assy front floor side inner LH 25. Reinforcement assy front seat front RH
11. Sill assy front floor side inner RH 26. Member assy front floor rear LH
12. Panel assy front floor LH 27. Member assy front floor rear RH
13. Panel assy front floor RH 28. Hanger front muffler
14. Member assy front floor lower LH 29. Member assy backbone rear
15. Member assy front floor lower RH 30. Reinforcement assy parking brake

BODY CONSTRUCTION 1
REAR FLOOR WBR001BCONS11010
DOIQB001R11010

1 BODY CONSTRUCTION
Body Components
1. Sill rear floor side inner LH 31. Brace rear wheel house outer RH
2. Sill rear floor side inner RH 32. Brace rear wheel house outer LH
3. Extension rear floor front upper 33. Reinforcement assy rear wheel house inner LH
4. Extension assy rear floor front lower 34. Reinforcement assy rear wheel house inner RH
5. Reinforcement assy rear floor side member 35. Reinforcement assy rear floor side member
front center RH rear center LH
6. Reinforcement assy rear floor seat mounting 36. Reinforcement assy rear floor side member
LH rear center LH
7. Reinforcement assy rear floor seat mounting 37. Reinforcement spring house rear LH
RH 38. Reinforcement spring house rear RH
8. Reinforcement assy NGV tank bracket mount- 39. Bracket fuel tank rear LH
ing LH 40. Bracket fuel tank rear RH
9. Reinforcement assy NGV tank bracket mount- 41. Hanger rear muffler rear LH
ing RH 42. Hanger assy rear muffler rear RH
10. Reinforcement rear floor side member front 43. Hook shipping
center LH 44. Plate assy ventilation plug
11. Reinforcement rear floor side member front 45. Reinforcement assy rear floor side member
center RH rear LH
12. Bulkhead extension rear floor front LH 46. Reinforcement assy rear floor side member
13. Bulkhead extension rear floor front RH rear RH
14. Bracket assy fuel tank front 47. Extension rear floor side member LH
15. Reinforcement assy rear seat front hinge 48. Extension rear floor side member RH
16. Bracket assy splash shield LH 49. Reinforcement assy side member rear floor
17. Bracket assy splash shield RH rear LH
18. Hanger assy rear muffler front 50. Reinforcement assy side member rear floor
19. Reinforcement assy rear seat mounting center rear RH
20. Bracket spare tyre assy 51. Reinforcement assy towing hook
21. Reinforcement assy rear floor side member 52. Bracket rear spring LH
front center LH 53. Bracket rear spring RH
22. Extension brace rear wheel house LH 54. Brace rear wheel house inner LH
23. Exterior brace rear wheel house RH 55. Brace rear wheel house inner RH
24. Bracket assy brake hose LH 56. Panel rear wheel house inner LH
25. Bracket assy brake hose RH 57. Panel rear wheel house inner RH
26. Extension cross member rear floor side LH 58. Panel assy rear floor
27. Extension cross member rear floor side RH 59. Panel assy rear floor (NGV)
28. Cross member rear floor
29. Side member assy rear floor LH
30. Side member assy rear floor RH

BODY CONSTRUCTION 1
SIDE BODY WBR001BCONS11011
FRONT SIDE STRUCTURE
DOIQB001R11011
Body Components
1. Reinforcement assy front pillar inner lower 12. Bulkhead center pillar inner 1
LH/RH 13. Panel assy front pillar inner upper LH/RH
2. Extension side sill front LH/RH 14. Reinforcement assy front pillar upper LH/RH
3. Bracket assy FEM adapter LH/RH 15. Bulkhead center pillar inner 2
4. Reinforcement assy fender shield outer rear 16. Reinforcement assy center pillar outer LH/RH
LH/RH 17. Panel assy front pillar front inner upper LH/RH
5. Bulkhead side sill outer LH/RH 18. Panel assy center pillar inner LH/RH
6. Reinforcement side sill outer front LH/RH 19. Reinforcement side sill extension LH/RH
7. Bracket assy 1st R/S/belt rtcr LH/RH 20. Reinforcement assy door striker
8. Reinforcement assy upper hinge front LH/RH 21. Rail assy roof side inner LH/RH
9. Reinforcement assy front door check arm
LH/RH
10. Pillar assy upper belt reinforcement LH/RH
11. Reinforcement side sill outer LH/RH

1 BODY CONSTRUCTION
REAR SIDE STRUCTURE WBR001BCONS11012
DOIQB001R11012
Body Components
1. Bracket assy fender mounting lower LH/RH 11. Brace rear shelf LH/RH
2. Bracket assy fender mounting 12. Panel rear wheel house outer LH/RH
3. Reinforcement assy door striker 13. Housing assy rear combi lower lamp LH/RH
4. Panel assy side outer LH/RH 14. Housing rear combi lamp LH/RH
5. Extension rear end lower LH/RH 15. Reinforcement trunk lid drain channel LH/RH
6. Hook rear seat A LH 16. Housing rear combi upper lamp LH/RH
7. Reinforcement rear pillar 17. Reinforcement striker LH/RH
8. Reinforcement side sill inner LH/RH 18. Pillar assy rear inner LH/RH
9. Panel assy quarter inner upper LH/RH 19. Bracket assy fuel filler neck
10. Reinforcement assy parcel sheft side LH/RH 20. Bracket assy fuel filler neck (NGV)

BODY CONSTRUCTION 1
REAR END PANEL WBR001BCONS11013
DOIQB001R11004
Body Components
1. Panel rear end inner 4. Bump stop bracket RH
2. Bump stop bracket LH 5. Panel assy rear end outer
3. Reinforcement assy trunk lid striker

1 BODY CONSTRUCTION
ROOF WBR001BCONS11014
DOIQB001R11005
Body Components
1. Reinforcement rail roof side LH 4. Panel roof
2. Reinforcement rail roof side RH 5. Rail roof middle
3. Rail roof front 6. Rail roof rear

BODY CONSTRUCTION 1
DOOR CONSTRUCTION WBR001BCONS11015
FRONT DOOR
DOIQB001R11006
Body Components
1. Panel front door outer LH/RH 6. Patch assy door hinge LH/RH
2. Bracket box pull handle 7. Reinforcement front door beltline outer LH/RH
3. Reinforcement front door side impact LH/RH 8. Sash assy front door window LH/RH
4. Reinforcement front door beltline inner LH/RH 9. Reinforcement front door latch LH/RH
5. Panel front door inner LH/RH

1 BODY CONSTRUCTION
REAR DOOR
DOIQB001R11007
Body Components
1. Panel rear door outer LH/RH 6. Patch assy door hinge LH/RH
2. Panel rear door inner LH/RH 7. Reinforcement rear door beltline inner LH/RH
3. Bracket box pull handle 8. Reinforcement rear door beltline outer LH/RH
4. Reinforcement assy rear door side impact 9. Sash assy rear door window LH/RH
LH/RH 10. Reinforcement rear door latch LH
5. Bracket glass rear door

BODY CONSTRUCTION 1
FRONT END MODULE (FEM) WBR001BCONS11016
DOIQB001R11015
The Front End Module (FEM) structure is a Hybrid Structure with a combination of metal and plastic
parts.
This makes the Front End Module (FEM) more rigid as well as being flexible.

1 BODY CONSTRUCTION
REINFORCEMENT ASSY SIDEMEMBER FRONT INNER
DOIQB001R11016
The Reinforcement Assy Sidemember Front Inner is designed to strengthen the assy sidemember
structure.
It is located within the assy sidemember structure between the Side Member Assy Front Inner LH/RH
and Side Member Assy Front Outer LH/RH.
Please refer page WBR001BCONS092 for the cross sectional view of the Reinforcement Assy
Sidemember Front Inner.

BODY CONSTRUCTION 1
SILENCER APPLICATION / 33
SILENCER APPLICATION WBR001BCONS11017
SILENCER APPLICATION LOCATIONS

In order to reduce vibration, noise and screen out heat from the exhaust gas, silencers are applied on
specific areas of the floor. The silencers which are also known as damping sheets or sound deadeners,
acts as a sound dampening material as well as absorbing the vibrations of the body panels while
driving.
NOTE
The silencer is a high-performance damping sheet. It is made out of asphalt, mica, heat cured resin
and so on to improve damping performance.
DOIQB001R11021

1 BODY CONSTRUCTION
/ 34 SILENCER APPLICATION
DOIQB001R11022
Symbol Description Thickness (mm) Weight (Kg)

1 Silencer front floor FRONT 3 1.357
1 Silencer front floor FRONT (LHD) 3 1.239
2 Silencer front floor CENTER 3 0.738
3 Silencer front floor REAR 3 0.644
4 Silencer center floor REAR 3 0.297
5 Silencer rear floor 3 0.507
6 Silencer rear wheel house inner FRONT 3 0.250
7 Silencer rear floor REAR 3 0.395
7 Silencer rear floor REAR (NGV —RH) 3 0.279
8 Silencer rear side outer (Install at body 1.6 0.139
shop)
9a Silencer rear wheel house inner REAR RH 1.6 0.098
9b Silencer rear wheel house inner REAR LH 1.6 0.254
10 Silencer rear floor trunk 3 1.473
11 Silencer rear wheel house 3 0.254

BODY CONSTRUCTION 1
DOOR DAMPING SHEET

FRONT DOOR
DOIQB001R11023
Symbol Description
* Door damping sheet
REAR DOOR
DOIQB001R11025
Symbol Description
* Door damping sheet
SOUND DAMPENING FOAM MATERIAL
SOUND DAMPENING FOAM MATERIAL USAGE LOCATIONS
The sound dampening foam materials have been installed into the upper and lower sections of the
front 'A' pillars, lower section of the center 'B' pillars, side roof rails and the rear wheelhouse arch to
shield from external noises.
CAUTION
The sound dampening foam materials are flammable and may burn when heated. Always observe
the following instructions:
• Never use a gas torch/burner to cut or burn the areas where the sound dampening foam materials
are used.
• Always use an air/electric powered saw to cut the areas where the sound dampening foam mater-
ials are used.
• Always remove any excess sound dampening foam materials from the cut areas before continuing
with the welding work.

1 BODY CONSTRUCTION
DOIQB001R11024
THERE ARE 2 TYPES OF SOUND DAMPENING FOAM MATERIAL USED IN THE VEHICLE.
• Ethylene Propylene Diene Monomer (EPDM) Expandable Foam
• Ethylene Vinyl Acetate (EVA) Expanding Seal
Symbol Description Description

1 Fender shield inner seal EPDM Expandable Foam
2 Front pillar upper inner seal EPDM Expandable Foam
3 Front pillar upper outer seal EPDM Expandable Foam
4 Front pillar lower inner filler LH EVA Expanding Seal
5 Front pillar lower inner filler RH EVA Expanding Seal
6 Center pillar lower inner filler LH EVA Expanding Seal
7 Center pillar lower inner filler RH EVA Expanding Seal
8 Quarter inner filler LH EVA Expanding Seal
9 Quarter inner filler RH EVA Expanding Seal
10 Rear pillar inner seal EPDM Expandable Foam
11 Rear pillar outer seal EPDM Expandable Foam

BODY CONSTRUCTION 1

1 BODY CONSTRUCTION
DOIQB001R11032

BODY DIMENSION AND MEASUREMENT METHOD 2
Content /1
2 BODY DIMENSION AND MEASUREMENT METHOD

BODY DIMENSIONS AND MEASUREMENT METHODS ........................ 2/2
TYPE A (PROJECTED DIMENSIONS) .............................................. 2/2
TYPE B (ACTUAL-MEASUREMENT DIMENSIONS) ............................. 2/2
TYPE A (PROJECTED DIMENSIONS) ................................................ 2/4

UNDER BODY ....................................................................... 2/4
TYPE B (ACTUAL MEASUREMENT DIMENSIONS) ............................... 2/11

UNDER BODY ....................................................................... 2/11
SUSPENSION INSTALLATION DIMENSIONS ..................................... 2/14
REAR BODY .......................................................................... 2/16
SIDE BODY ........................................................................... 2/19
ENGINE COMPARTMENT .......................................................... 2/23
INTERIOR ............................................................................. 2/25
REAR BODY .......................................................................... 2/27

/2 BODY DIMENSIONS AND MEASUREMENT METHODS
BODY DIMENSIONS AND

MEASUREMENT METHODS
WBR002BDIME11001
TYPE A (PROJECTED DIMENSIONS)

• Type A (projected dimensions) is the dimension
when a measurement location is projected onto
the plane.
NOTE:
The height indicates a distance from the assumed
standard line established 100 mm below the
DOIPB002R10001
lowest measurement point.
TYPE B (ACTUAL-MEASUREMENT
DIMENSIONS)
DOIPB002R10002
DOIPB002R10003
• Type B (actual-measurement dimensions) is the

actual distance between the measurement
points. Measure using a tracking gauge or a
measuring tape, etc.
NOTE:
• Make the lengths of the tracking gauge probes
the same (A=A’).
• Do not bend or twist the measuring tape.
1. Insert the tracking gauge probes securely into
the measurement holes.
2. When the standard dimensions in the illustra-
DOIPB002R10004
tion are enclosed by rectangle, this indicates

BODY DIMENSIONS AND MEASUREMENT METHODS /3
that the symmetrical left and right positions

have the same dimensions.
3. When using a notch for dimension measure-
ment, set the measuring point at the centre
of the notch.
4. The body centre points are shown for the
purpose of checking the position of the left
and right symmetry location.

/4 TYPE A (PROJECTED DIMENSIONS)
TYPE A (PROJECTED DIMENSIONS) WBR002BDIME11002
UNDER BODY
DOIQB002R11053

TYPE A (PROJECTED DIMENSIONS) /5
No. Standard measurement point Hole shape mm (in)

1 Center of front sub frame mounting hole O 14 mm (0.55 in)
2 Center of front side member mounting hole O 15 mm (0.59 in)
3 Center of front side member rear mounting 10 mm (0.39 in)
O
hole
4 Center of suspension sub frame mounting 14 mm (0.55 in)
O
hole
5 Center of brace assy front side member drain 25 mm (0.98 in)
O
hole
6 Center of bracket assy w/carrier mounting 20 mm (0.79 in)
O
hole
7 Center of side member assy front floor lower 15 mm (0.59 in)
O
drain hole
8 Center of cross member front floor front 20 mm (0.79 in)
O
lower drain hole
9 Center of reinforcement side sill outer O 25 mm (0.98 in)
10 Center of side member assy front floor lower 15 mm (0.59 in)
O
drain hole (rear)
11 Lower portion of side sill rear floor side inner 20 mm (0.79 in)
O
positioning hole
12 Center of side member assy rear floor drain 20 mm (0.79 in)
O
hole
O
hole
14 Center of ext cross member rear floor side 12 mm (0.47 in)
O
drain hole
O
hole
16 Rear portion of side member assy rear floor 20 mm (0.79 in) x 25 mm (0.98
positioning hole in)
17 Rear portion of ext rear floor side member 12 mm (0.47 in) x 16 mm (0.63
Measurement point Measurement point


DOIQB002R11011

SUSPENSION INSTALLATION DIMENSIONS WBR002BDIME11003
DOIQB002R11054


3 Center of front side member rear mounting O 10 mm (0.39 in)
hole
4 Center of suspension sub frame mounting hole O 14 mm (0.55 in)
7 Center of side member assy front floor lower O 15 mm (0.59 in)
drain hole
drain hole (rear)
18 Center of strut insulator O 80 mm (3.15 in)
19 Center of suspension bracket sub frame front O 14 mm (0.55 in)
mounting hole
20 Center of suspension bracket sub frame rear O
14 mm (0.55 in)
mounting hole
21 Center of suspension rear axle mounting hole O 14 mm (0.55 in)
24 Center of suspension rear shock absorber O
11 mm (0.43 in)
mounting hole
64 mm (2.52 in)
mounting hole
11 mm (0.43 in)
mounting hole

/ 10 TYPE A (PROJECTED DIMENSIONS)
DOIQB002R11016

TYPE B (ACTUAL MEASUREMENT DIMENSIONS) / 11
TYPE B (ACTUAL MEASUREMENT DIMENSIONS) WBR002BDIME11004
UNDER BODY
DOIQB002R11056

1 Center of front sub frame mounting hole O 14 mm (0.55 in)
2 Center of front side member mounting hole O 15 mm (0.59 in)
3 Center of front side member rear mounting O 10 mm (0.39 in)
hole
4 Center of suspension sub frame mounting O 14 mm (0.55 in)
hole
5 Center of brace assy front side member drain O 25 mm (0.98 in)
hole
6 Center of bracket assy w/carrier mounting O 20 mm (0.79 in)
hole
drain hole
8 Center of cross member front floor font lower O 20 mm (0.79 in)
drain hole
9 Center of reinforcement side sill outer O 25 mm (0.98 in)
drain hole (rear)

/ 12 TYPE B (ACTUAL MEASUREMENT DIMENSIONS)

11 Lower portion of side sill rear floor side inner O 20 mm (0.79 in)
positioning hole
12 Center of side member assy rear floor drain O 20 mm (0.79 in)
hole
hole
14 Center of ext cross member rear floor side O 12 mm (0.47 in)
drain hole
hole
16 Rear portion of side member assy rear floor 20 mm (0.79 in) x 23 mm (0.91
17 Rear portion of ext rear floor side member 12 mm (0.47 in) x 16 mm (0.63


SUSPENSION INSTALLATION DIMENSIONS WBR002BDIME11005
DOIQB002R11057

3 O 10 mm (0.39 in)
4 O 14 mm (0.55 in)
7 O 20 mm (0.79 in)
10 O 15 mm (0.59 in)
18 O 14 mm (0.55 in)
19 O 14 mm (0.55 in)
20 O 14 mm (0.55 in)
21 O 14 mm (0.55 in)
22 O 14 mm (0.55 in)
24 O 11 mm (0.43 in)
25 O 64 mm (2.52 in)
26 O 11 mm (0.43 in)


REAR BODY WBR002BDIME11006
DOIQB002R11018


27 Corner of roof panel — —
28 Body Center point of rear shelf panel O 9 mm (0.35 in)
29 Side inner trunk lid lipseam (front area) — —
30 Side inner trunk lid lipseam (rear area) — —
31 Corner of side outer panel — —
32 Center of rear combination lamp mounting hole — —
33 Center of trunk lid latch striker mounting hole O 9 mm (0.35 in)
(left side)
34 Center of trunk lid latch striker mounting hole O 9 mm (0.35 in)
(right side)
35 Center of rear bumper reinforcement mounting O 9 mm (0.35 in)
hole (upper)
36 Center of rear bumper reinforcement mounting O 9 mm (0.35 in)
hole (lower)

DOIQB002R11025

SIDE BODY WBR002BDIME11007
DOIQB002R11038


37 Front pillar positioning notch (Upper section) — —
38 Front pillar positioning notch (Lower section) — —
39 Front pillar rear positioning notch (Upper — —
section)
40 Front side sill rear positioning notch — —
41 Center pillar front positioning notch (Lower — —
section)
42 Upper roof rear door position notch (Front — —
section)
43 Center pillar rear position notch (Lower sec- — —
tion)
44 Rear side sill front position notch — —
45 Rear pillar positioning notch (Lower section) — —
46 Center of upper roof rear door positioning — —
notch (rear section)
47 Center of front door check mounting hole — 9 mm (0.35 in)
48 Center of front door striker mounting hole — 9 mm (0.35 in)
(Upper section)
49 Center of rear door check mounting hole — 9 mm (0.35 in)
50 Center of rear door switch mounting hole — 3 mm (0.12 in)
51 Center of front door upper hinge mounting — 9 mm (0.35 in)
hole (Rear section)
52 Center of front door lower hinge mounting — 9 mm (0.35 in)
hole (Upper section)
53 Center of rear door upper hinge mounting — 9 mm (0.35 in)
hole (Upper section)
54 Center of rear door lower hinge mounting — 9 mm (0.35 in)
hole (Front section)
55 Center of rear door lower hinge mounting — 9 mm (0.35 in)
hole (Rear section)
56 Center of rear door striker mounting hole — 9 mm (0.35 in)
(Lower section)



ENGINE COMPARTMENT WBR002BDIME11008
DOIQB002R11039

57 Center of stud bumper beam impact lower
O 8 mm (0.31 in)
section
58 Center of hole plate assy moulding FEM upper O 10 mm (0.39 in)
59 Center of battery tray mounting hole O 9 mm (0.35 in)
60 Center of fender panel mounting hole O 7 mm (0.28 in)
61 Center of front strut mounting hole O 12 mm (0.47 in)
62 Center of fender panel mounting hole O 10 mm (0.39 in)
63 Center of front deck garnish mounting hole O 9 mm (0.35 in)
64 Center of bracket pipe liquid (A) mounting
O 7 mm (0.28 in)
hole


INTERIOR WBR002BDIME11009
DOIQB002R11046

65 Center of front door check mounting hole O 10 mm (0.39 in)
66 Centre of front door striker mounting hole
O 15 mm (0.59 in)
(Upper section)
67 Centre of rear door striker mounting hole
O 15 mm (0.59 in)
(Upper section)
68 Centre of hole on center pillar (Upper section) O 5.5 mm (0.22 in)
69 Center of hole rear pillar
70 Center of body center point O 7 mm (0.28 in)


REAR BODY WBR002BDIME11010
DOIPB002R10010

No. Standard measurement point Hole Size (mm)

shape
56. Corner of roof panel - -
57. Body centre point of rear shelf panel - -
58. Centre of trunk lid hinge mounting hole (front) Round 9
59. Centre of trunk lid hinge mounting hole (rear) Round 9
60. Corner of side outer panel - -
61. Centre of rear combination lamp mounting hole Round 8
62. Centre of trunk lid latch striker mounting hole (left side) Round 6.6
63. Centre of trunk lid latch striker mounting hole (right side) Round 6.6
64. Centre of rear bumper reinforcement mounting hole (upper) Round 15 (left
(left side), side),
Oblong 15×17
(right (right side)
side)
65. Centre of rear bumper reinforcement mounting hole (lower) Round 15
DOIPB002R10042
DOIPB002R10044

DOIPB002R10043
DOIPB002R10060
DOIPB002R10057

DOIPB002R10046

WELDED PANEL REPLACEMENT 3
Content /1
3 WELDED PANEL REPLACEMENT

WELDED PANEL REPLACEMENT .................................................... 3/4
PLATE ASSY FEM MOUNTING .................................................... 3/4
REPAIR WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4
FENDER SHIELD ...................................................................... 3/5
REPAIR WELDS RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/5
REPAIR WELDS LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/7
FRONT SIDEMEMBER (PARTIAL REPLACEMENT) .............................. 3/7
REPAIR WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8
REINFORCEMENT FRONT PILLAR (DRIVER SIDE) .............................. 3/9
REPAIR WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/10
REINFORCEMENT FRONT PILLAR (DRIVER SIDE) INSTALLATION ........... 3/11
REINFORCEMENT FRONT PILLAR (PASSENGER SIDE) ......................... 3/13
REPAIR WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/14
REINFORCEMENT FRONT PILLAR (PASSENGER SIDE) INSTALLATION ..... 3/15
CENTRE PILLAR ..................................................................... 3/18
REPAIR WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/18
CENTER PILLAR ...................................................................... 3/19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/19
SIDE SILL .............................................................................. 3/22
REPAIR WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/23
QUARTER OUTER ...................................................................... 3/25

WELDING POINTS ................................................................... 3/25
NOTE ON REPAIR WORK .......................................................... 3/26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/26

QUARTER PANEL, OUTER .......................................................... 3/27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/27
REAR END PANEL ...................................................................... 3/28

WELDING POINTS ................................................................... 3/28

REAR END PANEL ................................................................... 3/29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/30
REAR FLOOR ......................................................................... 3/30
REPAIR WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/34
QUARTER INNER ...................................................................... 3/35

WELDING POINTS ................................................................... 3/35
NOTE ON REPAIR WORK .......................................................... 3/38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/38
WELDED PANEL REPLACEMENT ................................................... 3/40

ROOF PANEL ......................................................................... 3/40
REPAIR WELDS AND SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/41
FRONT DOOR OUTER PANEL ..................................................... 3/42
REPAIR WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/43

/2 Content
ADHESIVE AND SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/44

REAR DOOR OUTER PANEL ....................................................... 3/44
REPAIR WELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/45

Content /3
NOTE

/4 WELDED PANEL REPLACEMENT
WELDED PANEL REPLACEMENT WBR003CMEMB11001
PLATE ASSY FEM MOUNTING
DOIQB003R12002
REPAIR WELDS
DOIQB003R12003

WELDED PANEL REPLACEMENT /5
FENDER SHIELD WBR003FENDS11001
DOIQB003R12002
REPAIR WELDS RH
DOIQB003R12004

REPAIR WELDS LH
DOIQB003R12005

REMOVAL WBR003FENDS11002
The welding point between front sidemember

inner and dash panel extension is hidden by the
dash crossmember extension upper . Therefore,
when removing the front side member, remove
the dash crossmember extension upper in ad-
vance.
Symbol Description
Dash crossmember extension
A
upper
DOINB003R09149
INSTALLATION
1. Remove the front sidemember brace lower,
suspension crossmember bracket rear and
dash crossmember extension lower from the
new front sidemember.
2. Remove the dash crossmember extension
upper from the new front side member and
install the front side member , and then in-
stall the dash crossmember extension upper.
Symbol Description
Dash crossmember exten-
A
sion upper
B Front
DOINB003R09150
FRONT SIDEMEMBER (PARTIAL REPLACEMENT) WBR003CMEMB11002
DOINB003R09146

REPAIR WELDS
DOIQB003R12006

DOIQB003R12020
REINFORCEMENT FRONT PILLAR (DRIVER SIDE) WBR003FPILL11001
DOINB003R09090

/ 10 WELDED PANEL REPLACEMENT
REPAIR WELDS
DOIQB003R12021

WELDED PANEL REPLACEMENT / 11
DOIQB003R12022
REINFORCEMENT FRONT PILLAR (DRIVER

SIDE) INSTALLATION WBR003FPILL11002
1. To reinforce the strength of the front pillar

cut area, cut the side outer panel 100 mm
(3.94 in) above the cut-out part and front
pillar reinforcement outer upper 50 mm (1.97
in) above the cut-out part.
Symbol Description
A Side outer panel
B Front pillar reinforcement
DOINB003R09098 outer upper

2. To reinforce the strength of the side sill cut

area, cut the side outer panel 100 mm (3.94
in) behind the cut-out part and side sill rein-
forcement 50 mm (1.97 in) behind the cut-
out part.
Symbol Description
A Side outer panel
B Side sill reinforcement
3. Cut the new front pillar inner upper by
aligning it with the body side, and then as-
semble it with the new front pillar inner
DOINB003R09099
lower and install it to the body. After that
install the front floor side sill inner front.
4. Cut the new front pillar reinforcement outer
upper in alignment with the body-side and
install it.
Symbol Description
A Front pillar reinforcement
upper
DOINB003R09100
5. To prevent the foam materials dripping in

filling them, apply urethane in the area
shown in the figure to bury the inside of the
front pillar.
Symbol Description
A Urethane
DOINB003R09101

6. CAUTION:
Weld and repair if the side sill reinforcement
front is damaged.
Cut the new side sill reinforcement and the
side sill reinforcement front by aligning them
with the cut area of side sill reinforcement
in the body side.
Next, cut only the side sill reinforcement 100
mm (3.94 in) forwards from the cut area to
create a cover, and then cut the side sill rein-
forcement front 50 mm (1.97 in) backwards
from the cut area.
DOINB003R09102
Symbol Description
A Side sill reinforcement front
B Cover
C Side sill reinforcement
7. To install the side sill reinforcement, weld
the side sill reinforcement front, and then
weld the cover of side sill reinforcement.
Symbol Description
B Cover
DOINB003R09103
REINFORCEMENT FRONT PILLAR (PASSENGER SIDE) WBR003FPILL11003
DOINB003R09083

REPAIR WELDS
DOIQB003R12023

DOIQB003R12024
REINFORCEMENT FRONT PILLAR

(PASSENGER SIDE) INSTALLATION
WBR003FPILL11004
1. To reinforce the strength of the front pillar

(3.94 in) above the cut-out part and front
pillar reinforcement outer upper 50 mm (1.97
in) above the cut-out part.
Symbol Description
A Side outer panel
B Front pillar reinforcement
DOINB003R09091
outer upper


area, cut the side outer panel 100 mm (3.94
in) behind the cut-out part and side sill rein-
forcement 50 mm (1.97 in) behind the cut-
out part.
Symbol Description
A Side outer panel
B Side sill reinforcement
3. Cut the new front pillar inner upper by
aligning it with the body side, and then as-
semble it with the new front pillar inner
DOINB003R09092
lower and install it to the body. After that
install the front floor side sill inner front.
4. CAUTION:
Weld and repair if the front pillar support is
damaged.
Cut the new front pillar reinforcement outer
upper and the front pillar support by align-
ing them with the front pillar reinforcement
outer upper of the body side.
Next, cut only the front pillar reinforcement
outer upper 100 mm (3.94 in) downwards
from the cut area to create a cover, and then
cut the front pillar support 50 mm (1.97 in)
above the cut area.
DOINB003R09093
Symbol Description
A Cover
B Front pillar support
C Front pillar reinforcement
outer upper
5. To install the front pillar reinforcement outer
upper, weld the front pillar support, and
then weld the cover of front pillar reinforce-
ment outer upper.
Symbol Description
A Cover
B Front pillar support
DOINB003R09094

6. To prevent the foam materials dripping in

filling them, apply urethane in the area
shown in the figure to bury the inside of the
front pillar.
Symbol Description
A Urethane
DOINB003R09095
7. CAUTION:
front is damaged.
Cut the new side sill reinforcement and the
with the cut area of side sill reinforcement
in the body side.
Next, cut only the side sill reinforcement 100
mm (3.94 in) forwards from the cut area to
create a cover, and then cut the side sill rein-
forcement front 50 mm (1.97 in) backwards
from the cut area.
DOINB003R09096
Symbol Description
B Cover
C Side sill reinforcement
Symbol Description
B Cover
DOINB003R09097

CENTRE PILLAR WBR003CPILL11001
DOINB003R09089
REPAIR WELDS
DOIQB003R12007

CENTER PILLAR WBR003CPILL11002
REMOVAL
After removing the center pillar, remove the
center pillar inner left on the body side.
Symbol Description
A Center pillar inner
DOINB003R09104
INSTALLATION
1. To reinforce the strength of the center pillar
(1.97 in) above the cut-out part.
Symbol Description
B Side outer panel
1 50 mm (1.97 in)
DOINB003R09105

area, cut the side outer panel front 90 mm
(3.54 in) forwards and the side sill reinforce-
ment 40 mm (1.57 in) forwards from the cut-
out part in the front side. Cut the side outer
panel rear 50 mm (1.97 in) behind the cut-
out part in the rear side.
Symbol Description
A Front side
B Rear side
C Side outer panel front
D Side sill reinforcement
E Side outer panel rear
1 40 mm (1.57 in)
2 50 mm (1.97 in)
3 90 mm (3.54 in)
Caution
front is damaged
DOINB003R09106

3. Cut the new side sill reinforcement and the

to the cut area of side sill reinforcement in
the body side. Next, cut only the side sill re-
inforcement 100 mm (3.94 in) behind the cut
area to create a cover, and then cut side sill
reinforcement front 60 mm (2.36 in) forwards
from the cut area of the side sill reinforce-
ment.
Symbol Description
A Side sill reinforcement
DOINB003R09107 B Side sill reinforcement front
C Cover
1 60 mm (2.36 in)
2 100 mm (3.94 in)
DOINB003R09108

5. Cut the new center pillar reinforcement up-

per by aligning them with the cut-out part
of body side, and then weld the center pillar
reinforcement outer from outside and rear
door hinge reinforcement upper from inside
respectively.
Symbol Description
E center pillar reinforcement
outer
F Rear door hinge reinforce-
ment upper
DOINB003R09109
6. After assembling the new center pillar outer,

to prevent the foaming materials from drip-
ping in the area shown in figure of the in-
structions, adhere the urethane foam to fill
(bury) the interior portion of the center pil-
lar.
Symbol Description
G Urethane foam
DOINB003R09110
7. After assembling the new center pillar inner,

seal the hole and flange with bolt and sheet-
metal tape and then fill the hole with foam
materials as shown in the figure of the in-
structions.
Foam: 3M ATD ULTRAPRO Panel foam – Yel-
low
DOINB003R09111

8. Wait 2 hours after filling the foam materials

to remove the bolt and sheet-metal tape,
then melt the foam materials with a solder-
ing gun. This is to ensure that a clip, or any
other trim items can be inserted easily in the
hole filled with foam materials.
DOINB003R09112
SIDE SILL WBR003SSILL12001
DOINB003R09116

REPAIR WELDS
DOIQB003R12008

DOIQB003R12009
SIDE SILL WBR003SSILL12002
Partial replacement of side sill is

Note possible depending on the range
of damage.
Cut the side sill reinforcement by
displacing 50 mm (1.97 in) from
Caution
the butt welding area with the
side outer panel.
DOINB003R09118

QUARTER OUTER / 25
QUARTER OUTER WBR003QPOUT12001
WELDING POINTS
DOIPB003R10061
CAUTION:
When repairing the area using sound dampening foam material do not use firing tools since the
sound dampening foam material may burn.
DOIQB003R12010

/ 26 QUARTER OUTER
NOTE ON REPAIR WORK

INSTALLATION
When installing the new quarter panel outer
parts, perform the following procedures.
1. Machine the body loose panel cushion
(MR535301 or MR435765) for replacement
as shown and apply it to the body side be-
cause the sound dampening foam material
cannot be filled into the wheel arch.
DOIPB003R10047
2. Apply the body sealant in advance to the

areas as shown.
DOIPB003R10068

NOTE:
Partial replacement is possible depending on the
range of damage.
DOIPB003R10069
WELDED PANEL REPLACEMENT

WBR003QPOUT12002
QUARTER PANEL, OUTER

REMOVAL
When replacing the gate pillar reinforcement,
cut it 50 mm (1.97 in) downwards from the cut
area of rear gate pillar.
Symbol Description
A Gate pillar reinforcement
1 50 mm (1.97 in)
DOINB003R09125
INSTALLATION
1. To reinforce the strength of the rear gate
pillar cut area, cut the side outer panel 100
mm (3.94 in) above the cut-out part.
Symbol Description
B Side outer panel
1 100 mm (3.94 in)
DOINB003R09126
2. When assembling the new rear quarter outer

panel, apply in advance body sealant to the
areas shown in the figure of the instructions
. In addition to prevent the foam materials
from dripping, apply urethane foam to bury
the inside of the wheel arch.
Symbol Description
C Left side
D Urethane foam
E Body sealant
DOINB003R09127

/ 28 REAR END PANEL
3. Assembly the quarter outer panel, bolt and

tape the hole and flange with aluminum
tape, then fill the hole with foam materials
as shown in the figure of the instructions.
Foam: 3M ATD ULTRAPRO panel foam yel-
low.
DOINB003R09128
4. Wait 2 hours after filling the foam materials

to remove the bolt and aluminium tape.
Then melt the foam materials with a solder-
ing gun so a clip, etc. can thoroughly be in-
serted in the hole that was clogged with
foam materials, to bore open the hole.
DOINB003R09112
REAR END PANEL WBR003REPAN12001
WELDING POINTS
DOIPB003R10055

DOIQB003R12012
WELDED PANEL REPLACEMENT

WBR003REPAN12002
REAR END PANEL

REMOVAL
After removing the rear end outer panel to rein-
force the strength of the rear end panel cut area,
cut the rear end inner panel 30 mm (1.18 in)
Centre of vehicle side from the rear end outer
panel cut areas to remove it.
Symbol Description
DOINB003R09133 A Rear end inner panel
B Rear end outer panel
1 30 mm (1.18 in)

INSTALLATION
Remove the muffler hanger bracket rear from
the new rear end inner panel. Cut and install the
rear end inner panel while aligning it with the
cut area of body side , and then install the
muffler hanger bracket rear.
Symbol Description
A Side outer panel
DOINB003R09134
REAR FLOOR WBR003RFLOO12001
DOINB003R09135

REPAIR WELDS
DOIQB003R12013

DOIQB003R12014

DOIQB003R12015
REMOVAL WBR003RFLOO12002
1. When cutting the rear floor pan, cut it 40

mm (1.57 in) behind the body centre point
as shown.
Symbol Description
A Rear end inner panel
1 40 mm (1.57 in)
DOINB003R09138

2. Remove the seat pan support and shipping

bracket (right side) on the cut area in ad-
vance when cutting the rear floor sidemem-
ber.
Symbol Description
B Seat pan support
C Right side
D Shipping bracket
DOINB003R09139
3. Cut the rear floor side member 280 mm

(11.02 in) forward from the hitch member
mounting hole. In addition, cut the rear floor
side pan in the same area.
Symbol Description
1 280 mm (11.02 in)
DOINB003R09140
INSTALLATION
1. Remove the seat pan reinforcement from the
new rear floor crossmember.
Symbol Description
A Side outer panel
DOINB003R09141

QUARTER INNER / 35
2. When assembling the new quarter inner ex-

tension lower, apply in advance body sealant
to the areas shown in the figure of the in-
structions.
Symbol Description
B Body sealant
DOINB003R09142
QUARTER INNER WBR003QINNE12001
WELDING POINTS
DOIPB003R10062

/ 36 QUARTER INNER
DOIQB003R12017
NOTE:
Refer to the Quarter Outer section for the welding points with the quarter outer.

QUARTER INNER / 37
DOIQB003R12018

/ 38 QUARTER INNER
DOIQB003R12019
NOTE ON REPAIR WORK

INSTALLATION
DOIPB003R10049
1. When installing the new quarter panel inner parts, machine the body loose panel cushion
(MR535301 or MR435765) as shown and apply it to the body side to prevent the sound dampening
foam material from dropping when the material is filled into the rear pillar in the next process.

QUARTER INNER / 39
DOIPB003R10046
2. When installing the new rear pillar reinforcement lower parts, machine the body loose panel
cushion (MR535301 or MR435765) for replacement as shown and apply it to the body side because
the sound dampening foam material cannot be filled into the rear pillar reinforcement lower.
DOIPB003R10048
3. Assemble the quarter panel inner, bolt and tape the hole and flange with aluminium tape, then
fill the hole with sound dampening foam material as shown in the figure of the instructions.
Sound dampening foam material:
3M ATD ULTRAPRO Panel foam-Yellow

DOIPB003R10001
4. Wait 2 hours after filling the sound dampening foam material to remove the bolt and aluminium
tape, then melt the sound dampening foam material with a soldering gun so a clip, etc. can
thoroughly be inserted in the hole filled with sound dampening foam material.
WELDED PANEL REPLACEMENT WBR003ROOFP12001
ROOF PANEL
DOINB003R09113

REPAIR WELDS AND SEALANT
DOINB003R09114

DOINB003R09115
FRONT DOOR OUTER PANEL WBR003FDOUT12001
DOINB003R09122

REPAIR WELDS
DOINB003R09130

ADHESIVE AND SEALANT
DOINB003R09131
REAR DOOR OUTER PANEL WBR003RDOUT12001
DOINB003R09143

REPAIR WELDS
DOINB003R09144

DOINB003R09145

CORROSION PROTECTION 4
Content /1
4 CORROSION PROTECTION
BODY SEALANT APPLICATION ..................................................... 4/2
SEDAN ................................................................................. 4/2
SEALANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/3
General Portion ..................................................................... 4/4
Corner Portion ....................................................................... 4/4
Description of Application Area ................................................. 4/5
PVC UNDERCOAT APPLICATION .................................................... 4/16

POLYVINYL CHLORIDE (PVC) UNDERCOAT APPLICATION LOCATIONS ... 4/16
PVC UNDERCOAT APPLICATION AREA DESCRIPTION ........................ 4/17
CAVITY WAX INJECTION ............................................................. 4/19

CAVITY WAX INJECTION LOCATIONS ........................................... 4/19
ROCKER PANEL PRIMER APPLICATION ............................................ 4/24

ROCKER PANEL PRIMER APPLICATION LOCATION ........................... 4/24

/2 BODY SEALANT APPLICATION
BODY SEALANT APPLICATION WBR004COPRO11005
BODY SEALANT APPLICATION LOCATIONS

SEDAN
DOIQB004R11001

BODY SEALANT APPLICATION /3
DOIQB004R11002
SEALANT SPECIFICATIONS
The type of sealant used must have the below properties:
• Highly solid and no volume shrinkage
• Non-running
The sealant is usually used to seal sheet metal seams such as:
• drip rails on the roof
• floor (inner)
• floor (underbody)
• body side panels
• trunk or tailgate
• hood
• doors
Recommended types of body seam sealants
(Proton Part No. MS 990413)
• 3M Part No. 8531
• 3M Part No. 8646
• HENKEL SA1095
• TEROLAN #3330
• ASAHI RUBBER 2753
• NITTOKU M120, M90, ML60GX
• CEMEDINE HENKEL S947–1
• KOSHO 2490D
• CEMEDINE S902–5

• SUNSTAR 1573DC
NOTES WITH REGARD TO REPAIR WORK:
In places where the sealant can be directly seen on surfaces such as the drip rails, pillars, and where
the appearance of the paint surface is important, apply sealant or wipe away sealant after application
to make the amount of sealant even. Be careful not to cover the drain hole.
General Portion
DOIQB004R11026
Symbol Description
* Apply sealant securely so that it is not visible at the edge of the outer
panel.
To be wiped until surface is smooth.
Corner Portion

Symbol Description
* Apply sealant securely so that it is not visible at the edge of the outer panel.
Description of Application Area
Sealing lines are highlighted in bold.
Symbol Description
* Apply sealant securely so that it is not visible at the edge of the outer panel.
** Finish to be flat for waterproofing (for glass bonding).
Application Surfaces Application Surfaces

DOIQB004R11008

DOIQB004R11009

DOIQB004R11014

DOIQB004R11015

/ 10 BODY SEALANT APPLICATION
DOIQB004R11016

BODY SEALANT APPLICATION / 11
DOIQB004R11017

DOIQB004R11020

DOIQB004R11031

DOIQB004R11021

DOIQB004R11022
Marked with * : Apply sealant securely so that it is not visible at the edge of the outer panel. To be
wiped until surface is smooth.
Marked with ** : Finish to be flat for waterproofing (for glass bonding)

/ 16 PVC UNDERCOAT APPLICATION
PVC UNDERCOAT APPLICATION WBR004COPRO11006
POLYVINYL CHLORIDE (PVC) UNDERCOAT APPLICATION LOCATIONS

In order to provide rust, corrosion, chipping and vibration resistance, a special undercoat is applied
to certain areas of the body. After completing body repairs, restore this undercoat if necessary.
DOINB004R09055
Polyvinyl chloride (PVC) base undercoating

[ FILM THICKNESS OF AT LEAST 0.8 mm ( 0.03 in.) ]
NOTE
* : Mask the location before applying the undercoat because parts are to be mounted in these loca-
tions.
X: Polyvinyl chloride (PVC) base undercoating application area.

PVC UNDERCOAT APPLICATION / 17
DOINB004R09057
Polyvinyl chloride (PVC) base undercoating

[ FILM THICKNESS OF AT LEAST 0.8 mm ( 0.03 in.) ]
NOTE
* Mask the location before applying the undercoat because parts are to be mounted in these locations.
X: Polyvinyl chloride (PVC) base undercoating application area.
PVC UNDERCOAT APPLICATION AREA
DESCRIPTION
Symbol Description
Mask the location with a 30
mm Masking Tape before apply-
*
ing the undercoat.
Hole for splash shield rear
Polyvinyl chloride (PVC) base
X
undercoating application area.
DOINB004R09064

/ 18 PVC UNDERCOAT APPLICATION
Symbol Description
Mask the location with a 30
mm Masking Tape before apply-
*
ing the undercoat.
Hole for splash shield front
Polyvinyl chloride (PVC) base
X
undercoating application area.
DOINB004R09061

CAVITY WAX INJECTION / 19
CAVITY WAX INJECTION WBR004COPRO11007
CAVITY WAX INJECTION LOCATIONS
DOINB001R09017

/ 20 CAVITY WAX INJECTION
DOINB001R09016

Symbol Description
* : Cavity wax injection nozzle insertion openings and locations
x :Shaded area indicates cavity wax layer
In order to provide greater corrosion resistance, cavity wax injection is performed onto the lower
sections of the vehicle, such as the lower 'B' pillar, the side sill, doors, hood, tailgate, all hinges and
other panels which are of a hollow construction. If any of these panels are replaced, wax injection
must be performed on the new parts.
Recommended wax:
• Tectyl 506, 506T or ML
• Waxoyl
• Dinitrol 3122 or 3654–1
• Mercasol 831–ML
• Terotex
• HV200PLUS or HV300
1. Insert the Cavity Wax injection nozzle into the opening and inject the Cavity Wax as described in
the drawings below.
2. For wax injection locations with a rubber plug, please remember to reinstall the rubber plug after
the wax injection work is completed.
3. Be careful that the wax does not get onto other parts. Remove the seat belt retractor and the
door switch before injecting the wax into the lower part of the center 'B' pillar and into the side
sill.
4. Inject and properly apply the Cavity Wax onto the hinges as shown in the shaded area in the illus-
trations below.
CAUTION:
SAFETY PRECAUTIONS WHILE PERFORMING THE WAX INJECTION WORK
(1) Please be careful when handling the wax, if the wax enters the eyes please wash the eyes with a
lot of water and consult a doctor immediately.
(2) Please always wear your gloves while performing the wax injection work.
Symbol Description
* : Cavity wax injection nozzle insertion openings and locations
# : Shaded area indicates cavity wax layer
Cavity Wax Injection and Application Locations
DOIQB004R11033
DOIQB004R11032
Refer to Table A below

/ 22 CAVITY WAX INJECTION
DOIQB004R11035
DOIQB004R11034
Refer to Table A below
Table A
Symbol Description
A Panel Hood Outer
B Reinf Hood Lock Outer
C Panel Hood Inner
D Hood Hinge
E Reinforcement Fender Shield Outer Rear
F Panel Front Pillar Inner Upper
G Hood Hinge
H Panel Hood Inner
I Reinforcement Hood Hinge
DOIQB004R11037
DOIQB004R11036
Refer to Table B below
Table B
Symbol Description
A Panel Front Door Inner
B Panel Front Door Outer

DOIQB004R11041
DOIQB004R11040
Refer to Table C below
Table C
Symbol Description
A Panel Trunk Lid Outer
B Panel Trunk Lid Inner

/ 24 ROCKER PANEL PRIMER APPLICATION
ROCKER PANEL PRIMER APPLICATION WBR004COPRO11008
ROCKER PANEL PRIMER APPLICATION LOCATION

In order to provide a greater corrosion resistance and also to reduce the effects of stone chipping on
the lower side section of the vehicle, a layer of primer is applied to the rocker panel. After completing
body repairs, restore the primer as indicated in the illustration.
DOIQB004R11023
* : Rocker panel primer application area
DOIQB004R11024

ROCKER PANEL PRIMER APPLICATION / 25
Symbol Description
A Sill front floor side inner
B Reinforcement side sill outer front
C Reinforcement side sill outer
D Panel front door inner
E Panel front door outer
F Panel side outer
DOIQB004R11025
Symbol Description
A Panel side outer
B Rear wheel house outer
* : Rocker panel primer application area

/ 26 ROCKER PANEL PRIMER APPLICATION
NOTE

SYNTHETIC RESIN PARTS 5
Content /1
5 SYNTHETIC RESIN PARTS

LOCATION OF SYNTHETIC-RESIN PARTS .......................................... 5/2
[SEDAN] ............................................................................... 5/2
SYNTHETIC-RESIN PARTS ............................................................ 5/5
CHARACTERISTICS OF SYNTHETIC-RESIN PARTS ................................ 5/11

HOW TO DISTINGUISH TYPES OF SYNTHETIC-RESIN (PLASTIC) PARTS ... 5/11

/2 LOCATION OF SYNTHETIC-RESIN PARTS
LOCATION OF SYNTHETIC-RESIN PARTS WBR005RESIN11001
[SEDAN]
DOIPB005R10001

LOCATION OF SYNTHETIC-RESIN PARTS /3
Heat – resistant
No. Part Name Name of resin Abbreviation
temp. [°C (°F)]
1 Radiator grille
2 Door mirror outer cover
(colour)
3 Rear spoiler
4 Antenna base Acrylonitrile ethylene
AES 80
styrene
5 Front delta garnish
Acrylonitrile styrene ac-
6 Door mirror outer cover ASA (ASS) 80
rylate
(black)
7 Headlamp Polycarbonate PC 120
8 Rear door outside handle Polycarbonate+Polyethyl-
PC+PET 120
9 Front door outside handle ene terephthalate
10 Rear wheelhouse splash
shield High density polyethyl- PE-HD
70 – 90
ene (HDPE)
11 Front splash shield
12 High-mounted stoplamp Polymethyl methacryl PMMA 80
13 Front bumper core
14 Front door sash trim
15 Front door trim lower
16 Inside rear view mirror
17 Rear shelf trim
18 Rear end trim Polypropylene PP 80
19 Rear scuff plate
20 Rear door trim lower
21 Front scuff plate
22 Cowl side trim
23 Fender protector rear
24 Fog lamp bezel
25 Front bumper face
26 Front bumper grille
27 Rear bumper face Rubber denatured
PP+E/P 80
28 Rear door protect mould- polypropylene
ing
29 Front door protect mould-
ing
30 Front pillar trim Talc filled rubber modi-
PP+E/P-TD15 80
31 Rear pillar trim fied polypropylene (15%)
32 Side air dam Talc filled rubber modi-
PP+E/P-TD20 110
fied polypropylene (20%)
33 Front door trim upper
Talc filled polypropylene PP-TD10
34 Lower centre pillar trim 110 – 120
(10%) (PPF)
35 Rear door trim lower

/4 LOCATION OF SYNTHETIC-RESIN PARTS
Heat – resistant
No. Part Name Name of resin Abbreviation
temp. [°C (°F)]
36 Front deck garnish
37 Instrument panel
38 Front pillar trim
39 Upper centre pillar trim
40 Rear pillar trim Talc filled polypropylene PP-TD20
120 – 130
41 Floor console box cup (20%) (PPF)
holder
42 Floor console
43 Floor console panel
44 Floor console side cover
45 Roof drip moulding Polyvinyl chloride PVC 80
46 Rear mud guard
Thermoplastic elastomer TPO 80 – 100
47 Front mud guard
Note:
• If the material symbols designated by the ISO differ from the old symbols, both are given, with
the old symboling enclosed in brackets. ISO: International Standardization Organization.
• A slash (/) in the material symbol indicates that two different materials make two-layer construction.
A plus sign (+) indicates that the two different materials mix each other.
• The indicated heat-resistant temperature for parts which are composed of two or more types of
material is the value for the material with the lowest heat-resistant temperature.
• The material symbols for synthetic-resin parts are embossed on the parts in hidden places

SYNTHETIC-RESIN PARTS /5
SYNTHETIC-RESIN PARTS WBR005RESIN11002
The location and material of the principal synthetic-resin parts on the vehicle are as shown below:
LOCATION OF SYNTHETIC-RESIN PARTS
DOIQB005R11001
Exterior Parts
DESCRIPTION OF SYNTHETIC-RESIN PARTS
The Synthetic-Resin parts may be deformed if they are exposed to high temperatures. Therefore, remove
parts if necessary before carrying out any repairs.
Please observe the Heat-Resistance Temperatures of the Synthetic-Resin parts before carrying out any
repair work on or around these parts.
NO. PART NAME NAME OF RESIN ABBREVIATION HEAT – RESISTANCE

TEMPERATURE
[ °C (°F) ]
1 Mark, Top Acrylonitrile Butadiene ABS 80 (176)
2 Grille Garnish Chrome Styrene

/6 SYNTHETIC-RESIN PARTS

TEMPERATURE
[ °C (°F) ]
3 Bracket Licence Plate Polypropylene PP 80
4 Mesh Assy, Frt Bumper (176)
Lower
6 Mesh, Frt Bumper Upper
7 Fog Lamp Cover
8 Front Deck Garnish
9 Front Bumper High — Modulus Polypro- HMPP 80 – 100
pylene (176 – 212)
10 Headlamp Polycarbonate PC 120 (248)
11 Door Mirror Cover Polybutylene Terephtalate PP 150 (302)
12 Drip Rail Moulding Thermoplastic Elastomer TPO 80 (176)
(Olefine)
13 Tape Door Sash Front Polyvinyl Chloride PVC 80 (176)
14 Tape Door Sash Rear
15 Tape Door Sash Quarter
16 Lever Handle Polycarbonate + Acryloni- PC + ABS 112 – 142
trile Butadiene Styrene (234 – 288)
DOINB005R09002

Exterior Parts

TEMPERATURE
[ °C (°F) ]
1 Mark, Top Rr Acrylonitrile Butadiene ABS 80 (176)
2 Tail Gate Garnish Styrene
3 Rear Bumper Face • High - Modulus Polypro- • HMPP 80 - 100
pylene • PP +E/P-TD (176 - 212)
• Talc Filled Polypropylene
4 Door Outside Handles Polycarbonate + Poly- PC + PBT 130 - 140
butylene Terephthalate (266 - 284)
5 High Mounted Stop Lamp Polymethyl Metacrylate PMMA 80 - 100
(3rd Brake Lamp) (176 - 212)
6 Rear Combination Lamp
7 Front Splash Shield Polypropylene PP 80 (176)
(Wheelhouse Cover)
8 Rear Splash Shield
(Wheelhouse Cover)
9 Rear Spoiler Polyurethane PUR 80 - 100
(176 - 212)
DOINB005R09003
Interior Parts

/8 SYNTHETIC-RESIN PARTS

TEMPERATURE
[ °C (°F) ]
1 Delta Cover Acrylonitrile Butadiene ABS 80 (176)
2 Rear Control Switch Assy Styrene
3 Lock Knob
4 Room Lamp Polycarbonate PC 120 (248)
5 Map Lamp
6 Carpet, Deck Box Polyethylene Terephthalate • Polyester 115 (239)
• PET
7 Handle, Door Inside Polyacetal POM 140 (248)
8 Rear Vent Grille Assy Polypropylene PP 80 (176)
9 Front Door Trim Lh/Rh
10 Rear Door Trim Lh/Rh
11 Quarter Panel Trim Lh/Rh
12 Grip Assist Assy Lh/Rh
13 Rear View Mirror Assy
14 Ornament, Frt Door Lh/Rh Talc Filled Polypropylene PP+TALC 20% 120 - 130
15 Ornament, Rr Door Lh/Rh (20%) (248 - 266)
16 Cover Instrument Panel Talc Filled Polypropylene PP+TD 20% 120 - 130
Upper Lh/Rh (20%) (248 - 266)
17 Cowl Side Trim Lh/Rh
18 'A' Front Pillar Trim Lh/Rh
19 'B' Center Pillar Trim Upr
Lh/Rh
20 'B' Center Pillar Trim Lwr
Lh/Rh
21 'C' Rear Pillar Trim Lh/Rh
22 Deck Box Lid
23 Rr End Trim
24 Scuff Plate Trim Frt Lh/Rh
25 Scuff Plate Trim Rr Lh/Rh
26 Sunvisor Assy Lh/Rh Polyphenylene Ether PPE 130 - 140
(266 - 284)

DOINB005R09004
Interior Parts

TEMPERATURE
[ °C (°F) ]
1 Switch Assy Center Acrylonitrile Butadiene ABS 80 (176)
Mark, Top Styrene
2 Control Assy, Aircond
3 Panel Shift Lever Polycarbonate PC 120 (248)
4 Parking Lever Grip Polypropylene PP 80 (176)
5 Air Outlet Vents
6 Cup Holder
7 Center Console
8 Steering Column Lower
Cover
9 Steering Column Upper
Cover
10 Instrument Panel Talc Filled Polypropylene + PP+EPDM+T20 120 - 130
11 Glove Box Ethylene Propylene Diene (248 - 266)
Monomer
12 Floor Console Talc Filled Polypropylene PP+TALC 20% 120 - 130
(20%) (248 - 266)

/ 10 SYNTHETIC-RESIN PARTS

TEMPERATURE
[ °C (°F) ]
13 Footrest Talc Filled Polypropylene PP+TD 20% 120 - 130
(20%) (248 - 266)
14 Steering Wheel Polyurethane PUR 80 - 100
(176 - 212)
15 Parking Brake Cover Polyvinyl Chloride PVC 80 (176)
16 Shift Lever Cover
17 Gearshift Knob Thermoplastic Elastomer TPE 80 (176)
DOINB005R09005
Exterior Part - Front End Module (FEM)

Special Hybrid Component - Combination of Synthetic Resin and Steel

TEMPERATURE
[ °C (°F) ]
1 Front End Module Polyamide PA + STEEL PA : 140 - 160
(176 - 212)
NOTE:
If an infrared lamp is used for forced drying, cover the surrounding parts with a heat-resistant cloth.

CHARACTERISTICS OF SYNTHETIC-RESIN PARTS / 11
HEAT RESISTANCE TEMPERATURES OF ELECTRONIC COMPONENTS

The function of an electronic component can also become impaired if the parts are exposed to high
temperatures. If it appears that any electric or electronic parts will be exposed to temperature in excess
of 80° C during repair work, remove the part before proceeding with the repairs. Refer to the Chassis
Workshop Manual for the locations of the electronic components.
CHARACTERISTICS OF SYNTHETIC-RESIN PARTS WBR005RESIN11003
HOW TO DISTINGUISH TYPES OF SYNTHETIC-RESIN (PLASTIC) PARTS

There are various methods that can be used to distinguish between types of plastics, such as
(1) using a chemical solvent to check chemically,
(2) scratching the material to determine its make up and
(3) cutting off a small piece from a location that is not easily visible and burning it to observe the way
it burns.
The table below shows the combustion characteristics of some of the widely used Synthetic-Resin
parts.
Name of Plastic Abbrevi- Flame Color Combustion Condi- Self - extin- Odour
ation tion guishing
Polyvinyl Chloride PVC Yellow flame at Burns to black Yes Irritating
top Green flame residue acid odour
at bottom
Polyethylene PE Yellow flame at Burns clearly while No Candle-like
top Blue flame at melting odour
bottom
Polypropylene PP Yellow flame at • Burns briskly No Petroleum -
top Blue flame at and drips like odour
bottom • Small amount
of white
smoke
PUR Crackles and drips No Rubber -
Polyurethane Orange as it burns like odour
TRUR
Polycarbonate PC Yellow Cinders remain
To some extent Sweet
odour
Polyamide (Nylon) PA Yellow flame at Melts and drips Yes Strong
top Blue flame at formic acid
bottom odour
Polyester Resin UP Yellow Ashes remain No Styrene
odour
Glass Fiber-Rein- FRP Yellow Ashes with glass- No Differs ac-
forced Plastic fiber remnants re- cording to
main plastic type
Phenol Resin PF Yellow Ashes remain Yes Formalin
odour
ABS Resin ABS Orange Burns accompan- No Rubber
ied by foaming odour
and black smoke
High-Density Poly- HDPE Yellow flame at Burns clearly while No Candle-like
ethylene top Blue flame at melting odour
bottom

/ 12 CHARACTERISTICS OF SYNTHETIC-RESIN PARTS
Name of Plastic Abbrevi- Flame Color Combustion Condi- Self - extin- Odour
ation tion guishing
TPO Yellow flame at • Burns briskly No Petroleum -
Thermoplastic Elast- top Blue flame at and drips like odour
omer (TPE) bottom • Small amount
Olefine - Based of white
smoke
Thermoplastic Elast- TPS Orange Black smoke No Styrene
omer (TPE) odour
Polystyrene-Based
Thermoplastic Elast- TPU Orange Crackles and drips No Rubber -
omer (TPE) as it burns like odour
Polyurethane-Based
Thermoplastic Elast- TPE (PVC) Yellow flame at Burns to black Yes Irritating
omer (TPE) top Green flame residue acid odour
PVC-Based at bottom
Thermoplastic Elast- TEEE Red Burns and drips Yes Irritating
omer-Ether-Ester odour
(TEEE)
Polyether and/or
Polyester Based
Thermoplastic Elast- (TPAE) Yellow flame at Melts and drips Yes Strong
omer (TPE) top Blue flame at formic acid
Polyamide - Based bottom odour
PUR Orange Crackles and drips No Rubber
(R-RIM) as it burns. odour
Glass Fiber - Rein-
Ashes with glass-
forced RIM Urethane
fiber remnants re-
main

BODY COLOUR 6
Content /1
6 BODY COLOUR
BODY COLOR CHART ................................................................. 6/2
BODY COLOURING ................................................................... 6/3

BLACK PAINT ON FRONT WHEELHOUSE ....................................... 6/3
BLACK PAINT ON REAR WHEELHOUSE ......................................... 6/4
BLACK PAINT ON REAR PANEL ................................................... 6/4

6 BODY COLOUR
/2 BODY COLOR CHART
BODY COLOR CHART WBR006COLOR11001
Check the vehicle’s body color code, and then use this body color chart to determine the refinishing
paint supplier from which the color can be purchased.
Paint Used by Manufacturer

Engine compartment and luggage compartment color
Color Composition of Film
Color Color
Red Metallic Red Without clear
White Solid White Without clear
Silver Metallic Silver Without clear
Black Metallic Black Without clear

BODY COLOUR 6
BODY COLOURING /3
BODY COLOURING WBR006COLOR11002
DOIPB006R10001
BLACK PAINT ON FRONT WHEELHOUSE
DOIKB006R04295

6 BODY COLOUR
/4 BODY COLOURING
BLACK PAINT ON REAR WHEELHOUSE
DOIKB006R07002
BLACK PAINT ON REAR PANEL
DOIKB006R04298

WORKSHOP MANUAL
ELECTRICAL WIRING
CR FT
RA
D
Model YR 2012
Destination: MHR
Copyright ©
Perusahaan Otomobil
Nasional Sdn. Bhd.
WORKSHOP MANUAL -
Group Index /I
00 GENERAL ................................................................................... 00/1 - 00/20

2 HARNESS CONFIGURATION DIAGRAMS .......................................... 2/1 - 2/18
4 JUNCTION BLOCK ........................................................................... 4/1 - 4/27
6 POWER UNIT .................................................................................. 6/1 - 6/22
7 ENGINE AND TRANSMISSION MANAGEMENT SYSTEM .................... 7/1 - 7/24
8 EXTERIOR LIGHTING ....................................................................... 8/1 - 8/16
9 INTERIOR LIGHTING ......................................................................... 9/1 - 9/4
FT
10 DRIVER INFORMATION ............................................................... 10/1 - 10/10
11 WIPE AND WASH ......................................................................... 11/1 - 11/5
12 ASSISTANT MECHANISM ............................................................ 12/1 - 12/15
13 DRIVER AIDS ................................................................................ 13/1 - 13/5
14 DRIVING COMFORT .................................................................... 14/1 - 14/11
RA
D

GENERAL 00
Content /1
00 GENERAL
FOREWORD ............................................................................ 00/2

CONTENTS ............................................................................ 00/2
PAGE NUMBERS ..................................................................... 00/2
OPERATION AND TROUBLESHOOTING HINTS ................................. 00/2
MODELS ................................................................................ 00/3
FT
MODEL CODE ........................................................................ 00/3
OPERATING INSTRUCTIONS DOCUMENT ......................................... 00/3

1. BREAKDOWN OF THE FUNCTION INTO THREE DIAGRAMS: ............ 00/3
2. CONSTITUTION OF THE DIAGRAMS: ......................................... 00/4
HOW TO READ CONFIGURATION DIAGRAMS ................................... 00/5
HOW TO READ CIRCUIT DIAGRAMS .............................................. 00/6

RA
CIRCUIT DIAGRAMS ................................................................ 00/6
MARKINGS FOR CONNECTOR EARTHING ........................................ 00/10
ENGINE JUNCTION BLOCK AND PANEL FUSE BOX CONNECTORS DISAS- 00/13
SEMBLY SEQUENCE ...................................................................
WIRE AND CONNECTOR COLOUR CODES ........................................ 00/14

CONNECTOR CODING .............................................................. 00/14
WIRE CODING ....................................................................... 00/15
D
TYPE OF SYMBOL ..................................................................... 00/15
ABBREVIATION SYMBOLS ........................................................... 00/17

Abbreviation symbols used in wiring diagrams .............................. 00/17
Abbreviation symbols used for combination meter ......................... 00/17
Abbreviation symbols used for switches and relays ......................... 00/18
Abbreviation symbols used for Single Part Installation Position .......... 00/19
OPERATING INSTRUCTIONS DOCUMENT ......................................... 00/19

1. BREAKDOWN OF THE FUNCTION INTO THREE DIAGRAMS: ............ 00/19
2. CONSTITUTION OF THE DIAGRAMS: ......................................... 00/19

00 GENERAL
/2 FOREWORD
FOREWORD WEW000FWORD12001
This Electrical Wiring Manual contains information necessary for inspection and servicing of PROTON
electrical wiring in the form of wiring harness configuration diagrams and function-separated circuit
diagrams.
It is recommended that all service mechanics engaged in the servicing of the vehicle refer to the fol-
lowing publications as well as this manual.
Publication Type Publication No.

Workshop Manual Chassis RDCE-1200CR010
FT
Workshop Manual Engine Overhaul RDCE-110SP020-024
Workshop Manual Transmission & Clutch
Overhaul
·CVT transmission RDCE-09FZ6Y080-00
·Manual transmission RDCE-11GTRG080-00
Flat Rate Manual RDCE-1200CR030
PDI & Periodic Maintenance Manual RDCE-1200CR050
RA
Body Repair Manual RDCE-1200CR060
All information, illustration and product descriptions contained in this manual are current at the time
of publication. We, however reserve the right to make changes at any time without prior notice or
obligation.
HOW TO USE THIS MANUAL WEW000HUSEM12001
CONTENTS
The preceding page contains GROUP INDEX which lists the group/sub-group title and group/sub–group
number.
D
PAGE NUMBERS
All page number consist of two sets of numbers, two digits at the above and slash follows by number
at the bottom. The digits preceding at the above position indentify the number of the group. The
slash following with digits at the bottom represent the consecutive page number within the group.
This numbers can be found together on the top left or right of each page.
OPERATION AND TROUBLESHOOTING HINTS
In the module 3 CIRCUIT DIAGRAMS, the operation and troubleshooting hints are given on the previous
page or following page for each circuit where necessary.

GENERAL 00
MODELS /3
MODELS WEW000HREAD12001
4-DOOR SEDAN
Model code Engine model Transmission Fuel supply sys-
model tem
5MTT200A (2WD
SNBYRMA0
- 5-Speed M/T)
5MTT200A (2WD
SNJYRMA0
S4PH IAFM+ (1597 cm³ (97.45 - 5-Speed M/T)
FT
cu.in)) CVT2 (2WD - 6-
CR6 STBYRMA0 MPI
Speed)
CVT2 (2WD - 6-
STJYRMA0
Speed)
CVT3 (2WD - 7-
SDHARMA0 S4PH CFE (1561 cm³ (95.25 cu.in))
Speed)
MODEL CODE
RA
1 2 3 4 5 6 7 8 9 10 11
↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
C R 6 S N B Y R M A 0
No. Items Contents

1 Car segment C : Intermediate class
2 Platform R: Persona R
3 Engine size 6 : S4PH IAFM+ (1597 cm³ (97.45 cu.in))
6 : S4PH CFE (1561 cm³ (95.25 cu.in))
D
4 Body type S : 4–Door sedan

5 Transmission type T : 6 – Speed CVT2
D: 7 – Speed CVT3
B: Low Line
H : H - Line
Y : MPI DOHC IAFM+
7 Engine type
A : MPI DOHC CFE
Steering Wheel Loca- R : Right hand drive
8
tion L : Left hand drive
OPERATING INSTRUCTIONS DOCUMENT WEW000HREAD12002
1. BREAKDOWN OF THE FUNCTION INTO THREE DIAGRAMS:

• Wiring harness configuration diagrams.
• Single part installation position.
• Circuit diagrams.

00 GENERAL
/4 MODELS
2. CONSTITUTION OF THE DIAGRAMS:

Section Basic contents
Wiring harness config- Connector locations and harness wiring configurations on actual vehicles are
uration diagrams illustrated.
Locations are shown for earth points of relays, control units, sensors, diodes,
Single part installa-
check terminals, fusible links, fuses, etc.
tion position
In the parts lists, parts are listed in the alphabetical order.
Circuits from power supply to earth are shown completely, classified according
to system. There is a main division into power circuits, and circuits classified
FT
by system. The circuits classified by system also include operation and
troubleshooting hints.
• Power supply circuits.
Circuits from the battery to fusible link, dedicated fuses, ignition switch, gen-
eral purpose fuses, etc.
• Circuits classified by system.
For each system, the circuits are shown from fuse to earth, excluding the power
supply sections.
Circuit diagrams
RA
• Operation.
The normal operation of each system is briefly described, following the route
of current flow.
• Troubleshooting hints.
This is briefly explanation of the inspection points that serve as hints when
troubleshooting. Explanations of the circuits controlled by the electronic control
unit are omitted. Refer to the related publication as required.
• Junction block.
Here is the circuit for the entire junction block since only the part of the junc-
tion block needed is normally shown in each circuit diagram.
D

GENERAL 00
HOW TO READ CONFIGURATION DIAGRAMS /5
HOW TO READ CONFIGURATION DIAGRAMS WEW000HREAD12003
The wiring harness diagrams clearly show the connector locations and harness routines at each site
of actual vehicle.
FT
RA
D
DOIHH000R04001
Label Indication
A Denotes a section covered by a corrugated tube.
Denotes earth point.
Same earth number is used throughout circuit diagrams to facilitate search
B
of earth point. Refer to module 4.2 group 03 single part installation position
for details of earth points.
Denotes connector no, connector pins no and connector colour in bracket.
The same connector no. is used throughout the circuit diagrams to facilitates
connector location searches. The first alphabetical symbol indicates the loc-
C ation site of the connector and a number that follows is the unique number.
Furthermore, to make searching easier, number of connector pins and con-
nector colours (except in the case of milky white) are listed. Refer to section
wire and connector colour.
D The mark * shows the standard mounting position of wiring harness.

00 GENERAL
/6 HOW TO READ CIRCUIT DIAGRAMS
HOW TO READ CIRCUIT DIAGRAMS WEW000HREAD12004
CIRCUIT DIAGRAMS
NOTE:
The circuit of each system from fuse (or fusible link) to earth is shown. The power supply is shown at
the top and the earth at the bottom to facilitate understanding of the current flow.
FT
RA
D
DOINH000R09006
Label Indication
1 Indicates group/sub-group name
2 Indicates group/sub-group title
3 Indicates group/sub-group number
4 Indicates page number
5 Indicates circuit diagram title
6 Indicates power takeout (Refer section Abbreviation Symbols)

GENERAL 00
HOW TO READ CIRCUIT DIAGRAMS /7
Label Indication
7 Indicates harness junction point/bonded for another system. It corresponds to the junction
point number indicated on the destination system circuit diagram. Example: B-02 where,
B : harness name which is listed as below:
B : Body harness C : Control harness
E : Front End harness D : Door harness
F : Front harness G : Tail gate harness
R : Rear harness I : Instrument panel harness
and 02 represent the bonded number.
FT
8 Indicates the destination code system(Refer section Codes of the Destination System)
9 If no space is provided to show the connector symbol, the subjected connector No. is ex-
pressed with and the connector symbol is shown in another blank space.
10 An “X” at the end of a connector number indicates that the connector is connected to a
centralized junction that is shown in the section Centralized Junction.
11 In the case of single pole connector, the terminal number and connector symbol are omitted.
RA
12
Indicates that diagram is continued at on next page.
13 Indicates connector number. The same number as the wiring harness diagram is used.
14 Indicates the power supply in the control unit. If no voltage is displayed, this indicates system
voltage.
15 Indicates shield wire.
16 Indicates the operating conditions of the coolant temperature switch, etc.
17 Indicates continuity of harnesses on both pages.
D

00 GENERAL
/8 HOW TO READ CIRCUIT DIAGRAMS
CIRCUIT DIAGRAMS (continued)
FT
RA
D
DOINH000R09005
Label Indication
18 Indicates terminal No.
19 A broken-line indicates that these connectors are the same intermediate connectors.
20
Indicates that the diagram is continued from on the previous page.
21 In case two or more connectors are connected to same device, marking indicating the same
connector are connected by a broken line.
22 Indicates input/output to/from control unit (current flow direction).
where, 1 : input, 2 : output, 3 : input/output
DOIIH000R9004
23 Indicates current flow downward or upward as controlled by control unit.

24 Indicates harness junction point for an earth where the wire diameter or colour changes.
25 Indicates vehicle body earth point. (Same number as that of earth point in wiring harness
diagram and installation locations of individual parts).
26 Indicates wire size and colour(Refer section Wire and Connector Colour Code)

GENERAL 00
HOW TO READ CIRCUIT DIAGRAMS /9
Label Indication
27 Indicates that the terminal is a spare one in case the device (sensor in this case) is not sup-
plied according to the specifications.
28
The symbol Indicates that the actual harness connector is marked with numbering.
FT
RA
D

00 GENERAL
/ 10 MARKINGS FOR CONNECTOR EARTHING
MARKINGS FOR CONNECTOR EARTHING WEW000HREAD12005
FT
RA
D
DOINH000R09004

GENERAL 00
MARKINGS FOR CONNECTOR EARTHING / 11
Connector No. Item Symbol Contents
Double connector contour lines

indicate male connector terminal
Connector mark- DOIIH000R9005 DOIIH000R9006
1 M and single contour line indic-
ing
ates female terminal F as illus-
trated.
FT
DOIIH000R9007 DOIIH000R9008
The symbol indicates the connect-

or as viewed from illustrated dir-
ection.
• At the connection with a
DOINH000R09002 device, the connector symbol on
the harness side is shown.
RA
DOINH000R09003 • The (diamond symbol) is
Connector sym-
2 included for connector which is
bol marking
marked with terminal cavity
number.
Otherwise,
• For an intermediate connector,
male connector symbol is shown.
DOIIH000R09002
D
A connection between a device

3 and connector on the harness
side is either by direct insertion
DOIIH000R9011 DOIIH000R9012 in the device (direct connection
type, C) or by connection with a
harness connector on the device
Connector con-
4 side furnished (harness connec-
nection marking
tion type, D).
DOIIH000R9013 DOIIH000R9102 Meanwhile, intermediate con-
nector type, E is a connector
which connecting between the
5 harnesses. The three types are
indicated as illustrated.

00 GENERAL
/ 12 MARKINGS FOR CONNECTOR EARTHING
Connector No. Item Symbol Contents
Earth is either by body earth H,

7 device earth I or control unit in-
Earth marking
FT
terior earth J.
DOIIH000R9018 DOIIH000R9019 These are indicated as illustrated.
8
DOIIH000R9021
DOIIH000R9020
RA
D

GENERAL 00
ENGINE JUNCTION BLOCK AND PANEL FUSE BOX CONNECTORS DISASSEMBLY SEQUENCE / 13
ENGINE JUNCTION BLOCK AND

PANEL FUSE BOX CONNECTORS
DISASSEMBLY SEQUENCE
WEW000HREAD12006
1. Disengage the connector assembly from

housing.
• Pull lever lock by hand.
• The lock is released and connector assembly
is lifted up.
FT
• Pull the lever until it stops to disengage the
connector.
DOINH001R09004
2. Remove lever lock from connector assembly.

• Pull spread parts indicate of lever lock by
hand.
• Pull lever lock from connector by crossed
center of housing lock feature as shown on
RA
picture
DOINH001R09003
3. Remove wire dress cover.

• Using the special tool or hands release the
D
lock and remove wire dress cover.
DOINH001R09002
4. Remove lock TPA.

• Using the special tool release the lock and
remove lock TPA
DOINH001R09001

00 GENERAL
/ 14 WIRE AND CONNECTOR COLOUR CODES
5. Remove terminals from connector.

• Push connector lance using the special tool
release lock and remove the terminals.
FT
DOINH001R09005
WIRE AND CONNECTOR COLOUR CODES WEW000HREAD12007
Wire colour and connector colour are identified by the following colour codes.
Code Wire colour Code Wire colour

RA
B Black P Pink
Br Brown R Red
G Green Sb Sky Blue
Gr Gray V Violet
L Blue W White
Lg Light green Y Yellow
O Orange
CONNECTOR CODING
D
For connector the first appearence in bracket indicates the colour of the connector (if no colour listed
means that connectors colour are milky white) and the second code indicates number of connector
pins and connector location site symbol.
Example:
(2–Gr) : Number of connector pins and connector colour code

A-07 (connectors with no colour listed are milky white)
Which,
07 — indicates number specific to connector (serial/unique number)
A — indicates connector location site symbol. Where,
A: engine compartment
B: engine assy
C: dash panel
D: instrument panel
E: interior
F: door
G: luggage compartment
H: under rear floor

GENERAL 00
TYPE OF SYMBOL / 15
WIRE CODING
If a cable has two colours, the first of the two colour code characters indicates the basic colour (colour
of the cable coating) and the second indicates marking colour.
Example:
FT
RA
D
DOIHH000R04044
Label Indication
1 Marking colour
2 Basic colour
Wire size
3 1. No code indicates 0.5 mm² (0.0008 in²).
2. Cable colour code in parentheses indicates 0.3 mm² (0.0005 in²).
F : Flexible wire
4
T : Twisted wire
TYPE OF SYMBOL WEW000HREAD12008
Devices appearing in circuit diagrams are indicated by the following symbol.
Name Symbol Name Symbol

Connector
Battery (F) – Female side
DOIHH000R04045
(M) – Male side DOIHH000R04046

00 GENERAL
/ 16 TYPE OF SYMBOL
Name Symbol Name Symbol
Body earth Motor

DOIHH000R04047 DOIHH000R04048
Single bulb Horn

FT
Resistor Pulse generator
Diode Buzzer
Capacitor Chime
RA
Fuse Thyristor
Equipment Piezoelectric
earth device
D
Dual bulb Thermistor

Light emitting di-

Variable resistor
ode
Zener diode Photo diode

Crossing of
wires without Photo transistor
connection DOIHH000R04067 DOIHH000R04068
Crossing of wires
Fusible link
with connection
ECU interior
Transistor
earth
Speaker Coil

GENERAL 00
ABBREVIATION SYMBOLS / 17
ABBREVIATION SYMBOLS WEW000HREAD12009
Abbreviation symbols used in wiring diagrams

Abbreviation sym- Abbreviation
Meaning Meaning
bol symbol
ABS Anti lock breaking system ILL Illumination lamp
ACC Accessories IND Indicator lamp
ACU Air bag control unit J/B Junction block
ALTR Alternator MF Multi-purpose fuse
FT
ATRS Alarm tracking recovery system PF Instrument panel fuse box.
BATT Battery RHEO Rheostat
BCM Body control module RW BEC Routed wire bus electrical
center
CE Centralized electric box SC Short connector
CS Column switch SF Satellite fuse box
CPS Cam profile switch SP Spark plug
RA
DCC Dummy control circuit STC Stator coil
DF Dedicated fuse STR Starter
ECU Engine control unit TCU Transmission control unit
EF Engine room fuse box TCM Transmission control module
EGR Exhaust Gas Recirculation TR Turn signal, right
ELC-4 A/T Electronic control 4–speed TL Tirn signal, left
automatic transmission
EJB Engine junction block VR Voltage regulator
D
FC Field coil VIM Variable intake manifold

FL Fusible link VPS Vehicle position sensor
GND Earth VSS Vehicle speed sensor
ICM Integrated circuit module VTRS Vehicle tracking recovery
system
IPF Instrument panel fuse box IPF Instrument panel fuse box
IGN Ignition switch
Abbreviation symbols used for combination meter
Abbreviation symbol Meaning
BATT Battery
BEAM Upper beam indicator lamp
BRAKE Brake warning lamp
CHECK ENGINE Check engine warning lamp
CHG Charging warning lamp
CPS Cam profile switch
CPU Central processing unit
DOOR Door warning lamp
DR AJAR Door open
F/GA Fuel gauge
FUEL Fuel (remaining) warning lamp

00 GENERAL
/ 18 ABBREVIATION SYMBOLS

HAZARD Hazard warning indicator lamp
HIGH TEMP High temperature
ILL Illumination lamp
IG1 Ignition 1
LCD Liquid crystal display
OIL Oil pressure warning lamp
PARK BRAKE Parking brake
FT
R/FOG Rear fog indicator lamp
REED Reed switch (vehicle speed sensor)
SPEED Speedometer
TACHO Tachometer
T/GA Engine coolant temperature gauge
TURN (LH) Turn signal indicator lamp (L.H.)
TURN (RH) Turn signal indicator lamp (R.H.)
RA
VSS Vehicle speed sensor
Abbreviation symbols used for switches and relays
Name of switches and relays Abbreviation symbol Operation
Dimmer/passing switch LO Low beams ON
HI High beams ON
Lighting switch TAIL Position, tail, licence-plate and instrument
panel lamps ON
HEAD Headlamps ON
D
Room lamp switch DOOR Room lamp ON when a door is open

Condenser fan motor control re- HI Condenser fan motor operates at high speed
lay LO Condenser fan motor operates at low speed
Blower speed control switch LO Blower operates at low speed
ML Blower operates at medium low speed
MH Blower operates at medium high speed
HI Blower operates at high speed
Air conditioner switch ECONO 1st position (economical operation)
DRY 2nd position (full load operation)
Wiper switch LO Wipers operate at low speed
HI Wipers operate at high speed
INT Wipers operate intermittently
Turn signal switch BT Battery
LH L.H. turn signal lamps ON
RH R.H. turn signal lamps ON
Power window switch UP Window closed
DOWN Window opened
Door lock actuator/Door lock LOCK Door locked
control unit/Door lock key cylin- UNLOCK Door unlocked
der switch

GENERAL 00
OPERATING INSTRUCTIONS DOCUMENT / 19
Name of switches and relays Abbreviation symbol Operation

Remote controlled mirror switch LH L.H mirror operates
RH R.H mirror operates
UP Up direction
DOWN Down direction
RIGHT Right direction
LEFT Left direction
Others ON Switched on
FT
OFF Switched off
Abbreviation symbols used for Single Part Installation Position
BATT Battery
IM Intake manifold
BF Brake fluid tank
RA
CF Center member front deck
ECU/B ECU bracket
SRS/ECU Supplement Restraint System ECU
WT Washer tank
BATT(+) Battery (+ve) terminal
BLW Blower
SF Satellite fuse box
OPERATING INSTRUCTIONS DOCUMENT WEW000HREAD12010

D
1. BREAKDOWN OF THE FUNCTION INTO THREE DIAGRAMS:

• Wiring harness configuration diagrams.
• Single part installation position.
• Circuit diagrams.
2. CONSTITUTION OF THE DIAGRAMS:
Wiring harness config- Connector locations and harness wiring configurations on actual vehicles are
uration diagrams illustrated.
Locations are shown for earth points of relays, control units, sensors, diodes,
Single part installa-
check terminals, fusible links, fuses, etc.
tion position
In the parts lists, parts are listed in the alphabetical order.

00 GENERAL
/ 20 OPERATING INSTRUCTIONS DOCUMENT

Circuits from power supply to earth are shown completely, classified according
to system. There is a main division into power circuits, and circuits classified
by system. The circuits classified by system also include operation and
troubleshooting hints.
• Power supply circuits.
Circuits from the battery to fusible link, dedicated fuses, ignition switch, gen-
eral purpose fuses, etc.
• Circuits classified by system.
For each system, the circuits are shown from fuse to earth, excluding the power
FT
supply sections.
Circuit diagrams
• Operation.
The normal operation of each system is briefly described, following the route
of current flow.
• Troubleshooting hints.
This is briefly explanation of the inspection points that serve as hints when
troubleshooting. Explanations of the circuits controlled by the electronic control
unit are omitted. Refer to the related publication as required.
RA
• Junction block.
Here is the circuit for the entire junction block since only the part of the junc-
tion block needed is normally shown in each circuit diagram.
D

HARNESS CONFIGURATION DIAGRAMS 2
Content /1
2 HARNESS CONFIGURATION DIAGRAMS

ENGINE COMPARTMENT ............................................................ 2/2
ENGINE AND TRANSMISSION ...................................................... 2/5
DASH PANEL ........................................................................... 2/7
INSTRUMENT PANEL .................................................................. 2/9
INTERIOR ................................................................................ 2/11
FT
DOOR .................................................................................... 2/13
LUGGAGE COMPARTMENT .......................................................... 2/15
UNDER FLOOR ......................................................................... 2/17

RA
D

2 HARNESS CONFIGURATION DIAGRAMS
/2 WEW002CONFG11024 ENGINE COMPARTMENT
DOIQH002R11001
FT
RA
D [Connector symbol A-01 thru A-47]
ENGINE COMPARTMENT

Connector no. Connector description Connector no. Connector description
A-01 Brake fluid switch A-25x Back-up lamp (Micro relay K9)
A-02 Front wiper motor A-26 Front harness and body harness combination
A-03 ABS module A-27 UEC alternator
A-04 Front ABS sensor (LH) A-28 UEC battery
A-05 Battery wiring harness and engine wiring A-29 Front turn signal lamp (LH)
harness (2) combination
A-06
A-07
combination
D
UEC box (No.J1) and body wiring harness
UEC box (No.J2) and body wiring harness

combination
A-30
A-31
Head lamp (LH)
Fis (LH)
A-08 UEC box (No.J3) and body wiring harness Front harness (A) and front end harness
A-32
combination combination
A-09 UEC box (No.J4) and front wiring harness Front fog lamp (LH)
A-33
combination
A-10 UEC box (No.J5) and front wiring harness Horn (LH)
A-34
combination
RA
A-11 UEC box (No.J6) and engine wiring harness Horn (RH)
A-35
combination
A-12 UEC box (No.J7) and engine wiring harness Radiator fan
A-36
combination

A-13 UEC box (No.J8) and body wiring harness Hood open switch
A-37
combination
A-14 UEC box (No.J9) combination (Spare connect- Ambient temp
A-38
or)
A-15 UEC box (No.J10) and front wiring harness Compressor
A-39
FT
combination
A-16 UEC box (No.J11) and front wiring harness Fis (RH)
A-40
combination
A-17x Cooling fan HI (Mini relay K1) A-41 Front fog lamp (RH)
ENGINE COMPARTMENT
HARNESS CONFIGURATION DIAGRAMS
A-18x Cooling fan LO (Mini relay K2) A-42 Front turn signal lamp (RH)
A-19x Blower (Mini relay K3) A-43 Head lamp (RH)
A-20x Starter (Micro relay K4) A-44 Washer motor
/3
2
2
Connector no. Connector description Connector no. Connector description /4
A-21x Fuel pump (Micro relay K5) A-45 ABS bleeding
A-22x Fog lamp (Micro relay K6) A-46 Dual pressure switch
A-23x Low beam (Micro relay K7) A-47 Front ABS sensor (RH)
A-24x Main (Micro relay K8)
D
ENGINE COMPARTMENT
RA

FT
ENGINE AND TRANSMISSION /5
WEW002CONFG11027
DOIQH002R11002
FT
RA
D
ENGINE AND TRANSMISSION
[Connector symbol B-01 thru B-26]

2
Connector no Connector description Connector no Connector description /6
B-01 Front oxygen sensor B-14 Throttle body actuator
B-02 Ignition coil (4) B-15 Speed sensor*
B-03 Ignition coil (3) B-16 Back-up lamp switch*
B-04 Ignition coil (2) B-17 Coolant sensor
B-05 Ignition coil (1) B-18 Knock sensor
B-06 Injector (4) B-19 Alternator (B+)
B-07 Injector (3) B-20 Alternator (Solenoid)
B-08
B-09
Injector (2)
Injector (1)
D
Engine wiring harness and sub harness sensor
B-21
B-22
Oil pressure switch
Rear oxygen sensor*
B-10 B-23 Starter (B+)

wiring harness combination
B-11 Cam sensor B-24 Starter (Solenoid)
B-12 Crank sensor B-25 T-MAP sensor
ENGINE AND TRANSMISSION
B-13 Canister purge valve B-26 Vacuum actuator

* If so equipped
RA

FT
DASH PANEL /7
WEW002CONFG11030
DOINH002R09012
FT
RA
D [Connector symbol C-01 thru C-33]
DASH PANEL

2
Connector no. Connector description Connector no. Connector description /8
Instrument panel wiring harness and Engine
C-01 C-18 Wiper switch
wiring harness combination
C-02 BCM C1 C-19 Clock spring wheel switch
C-03 BCM C2 C-20 Clock spring
C-04 BCM C3 C-21 Turn signal switch
C-05 BCM C4 C-22 Headlamp switch
C-06 BCM C5 C-23 Steering lock switch
D
DASH PANEL
C-07 BCM C6 C-24 Ignition switch

Instrument panel wiring harness and IEC Box
C-08 C-25 TCU
J1 combination
C-09x Power window (Mini relay K1) C-26 ECU (A)
C-10x Power socket (Micro relay K2) C-27 ECU (B)
C-11x Gearshift solenoid (Micro relay K3) C-28 APS
C-12x Ignition (1) ON (Mini relay K8) C-29 Stop lamp switch
C-13x Ignition (2) ON (Mini relay K9) C-30 Steering angle sensor
Engine wiring harness and Body wiring har-
C-14 Diode start stop button C-31
RA
ness combination
Instrument panel wiring harness (B) and Body Instrument panel wiring harness (A) and Body
C-15 C-32
wiring harness (B) combination wiring harness (A) combination
C-16 Key ring antenna C-33 Antenna power

C-17 Fob holder
FT
INSTRUMENT PANEL /9
WEW002CONFG11031
DOINH002R09013
FT
RA
D [Connector symbol D-01 thru D-22]
INSTRUMENT PANEL

2
Connector no. Connector description Connector no. Connector description / 10
D-01 Passenger Air bag switch D-12 HVAC control unit (B)
D-02 Passenger Air bag D-13 Diagnostic connector
D-03 Switch assy (LH) D-14 Start stop button
D-04 Center switch D-15 Meter combination
D-05 Center box D-16 Incar sensor
D-06a Front power socket positif D-17 Switch assy (RH)
D-06b Front power socket negatif D-18 Alarm LED
D-07
D-08
D-09
Rear power socket
Audio (A)
Audio (B)
D D-19
D-20
D-21
HVAC subharness
Gearshift module (2)
P swicth
INSTRUMENT PANEL
D-10 Solar sensor D-22 Gearshift module

D-11 HVAC control unit (A)
RA

FT
INTERIOR / 11
WEW002CONFG11032
DOINH002R09011
FT
RA
D [Connector symbol E-01 thru E-20]
INTERIOR

2
E-01 Passenger curtain airbag (LH) E-11 Seat belt swicth (RH)
E-02 Center room lamp E-12 Parking brake switch
E-03 Driver curtain airbag (RH) E-13 Yaw rate sensor
E-04 Front map lamp E-14 Air bag control unit
E-05 Rain light sensor E-15 Seat belt switch (LH)
E-06 Door driver open switch E-16 Side air bag (LH)
INTERIOR
E-07 Driver side impact sensor (RH) E-17 Passenger side impact sensor (LH)
E-08
E-09
E-10
Pre-tensioner (RH)
D
Driver front lap pre-tensioner (RH)
Side air bag (RH)
E-18
E-19
E-20
Door passenger open switch
Passenger front lap pre-tensioner (LH)
Pre-tensioner (LH)
* If fitted
RA

FT
DOOR / 13
WEW002CONFG11033
DOIQH002R12001
FT
RA
D [Connector symbol F-01 thru F-24]
DOOR

2
Front door wiring harness (RH) (1) and body
F-01 F-13 Rear door latch actuator (RH)
wiring harness (1) combination
Front door wiring harness (RH) (2) and body
F-02 F-14 Rear door latch actuator (LH)
Rear door power window switch (LH) (Sub
DOOR
F-03 Front door speaker (RH) F-15

harness)
F-04 Front door power window motor (RH) F-16 Rear door power window motor (LH)
F-05
F-06
D
Driver Outside rear view mirror
Front door latch actuator (RH)

F-17
F-18
Rear door wiring harness (LH) (4) and body
Front door latch actuator (LH)
Driver outside rear view mirror (RH) (Sub
F-07 F-19 Front door speaker (LH)
harness)
F-08 Driver outside rear view mirror switch F-20 Front door power window switch (LH)
F-09 Front door power window switch (RH) F-21 Front door power window motor (LH)
Rear door wiring harness (RH) (3) and body Passenger outside rear view mirror (LH) (Sub
F-10 F-22
wiring harness (3) combination harness)
Front door wiring harness (LH) (2) and body
RA
F-11 Rear door power window motor (RH) F-23
Rear door power window switch (RH) (Sub
F-12 F-24 Passenger Outside rear view mirror
harness)

FT
LUGGAGE COMPARTMENT / 15
WEW002CONFG11034
DOINH002R09008
FT
RA
D
LUGGAGE COMPARTMENT
[Connector symbol G-01 thru G-19]

2
G-01 Defogger (-ve) <Single cable> G-11 Rear speaker (RH)
G-02 Rear lid lamp (LH) Body wiring harness and trunk lid wiring
G-12
harness combination
G-03 Licence lamp (LH) G-13 Rear combination lamp (RH)
G-04 Trunk lid latch actuator G-14 Diode
G-05 Trunk room lamp switch G-15 Trunk room lamp
G-06 Licence lamp (RH) G-16 Rear combination lamp (LH)
G-07
G-08
G-09
Rear lid lamp (RH)
Defogger (+ve)
D
High mounted stop lamp (HMSL)
G-17
G-18
G-19
Reverse sensor sub harness
Rear speaker (LH)
Rear door open switch (LH)
G-10 Rear door open switch (RH)
LUGGAGE COMPARTMENT
RA

FT
UNDER FLOOR / 17
WEW002CONFG11035
DOINH002R09007
FT
RA
D [Connector symbol H-01 thru H-03]
UNDER FLOOR

2
H-01 Rear ABS Wheel sensor (RH) H-03 Rear ABS Wheel sensor (LH)
H-02 Fuel pump
D
UNDER FLOOR
RA

FT
JUNCTION BLOCK 4
Content /1
4 JUNCTION BLOCK
UNDER HOOD ELECTRICAL CENTRE (UEC) ....................................... 4/2
PCB Schematic ....................................................................... 4/2
PCB Schematic <Continued> ...................................................... 4/3
UNDER HOOD ELECTRICAL CENTRE CONNECTOR ............................ 4/7
IP ELECTRICAL CENTRE (IEC) ........................................................ 4/8

PCB Schematic ....................................................................... 4/8
IP ELECTRICAL CENTRE CONNECTOR ............................................ 4/9
FT
ADVANCE BODY CONTROL MODULE (ABCM) .................................. 4/10
PCB Schematic ....................................................................... 4/10
PCB Schematic <Continued> ...................................................... 4/11
ADVANCE BODY CONTROL MODULE (ABCM) CONNECTOR ............... 4/18
FUSIBLE LINK & FUSES ............................................................... 4/20
MULTI-PURPOSE FUSE ................................................................ 4/23

RA
RELAY ................................................................................... 4/26
D

4 JUNCTION BLOCK
/2 UNDER HOOD ELECTRICAL CENTRE (UEC)
UNDER HOOD ELECTRICAL CENTRE (UEC) WEW004BLOCK12001
PCB Schematic
FT
RA
D
DOIQH004R12001

JUNCTION BLOCK 4
UNDER HOOD ELECTRICAL CENTRE (UEC) /3
PCB Schematic <Continued>
FT
RA
D
DOIQH004R12002

4 JUNCTION BLOCK
FT
RA
D
DOIQH004R12003

JUNCTION BLOCK 4
FT
RA
D
DOIQH004R12004

4 JUNCTION BLOCK
FT
RA
D
DOIQH004R12005

JUNCTION BLOCK 4
UNDER HOOD ELECTRICAL CENTRE CONNECTOR

Location of PIN SYMBOL on UNDER HOOD ELECTRICAL CENTRE connector
FT
RA
D
DOIQH004R12006

4 JUNCTION BLOCK
/8 IP ELECTRICAL CENTRE (IEC)
IP ELECTRICAL CENTRE (IEC) WEW004BLOCK12002
PCB Schematic
FT
RA
D
DOIQH004R12007

JUNCTION BLOCK 4
IP ELECTRICAL CENTRE (IEC) /9
IP ELECTRICAL CENTRE CONNECTOR

Location of PIN SYMBOL on IP ELECTRICAL CENTRE connector
FT
RA
D
DOIQH004R12008

4 JUNCTION BLOCK
/ 10 ADVANCE BODY CONTROL MODULE (ABCM)
ADVANCE BODY CONTROL MODULE (ABCM) WEW004BLOCK12003
PCB Schematic
FT
RA
D
DOIQH004R12009

JUNCTION BLOCK 4
ADVANCE BODY CONTROL MODULE (ABCM) / 11
FT
RA
D
DOIQH004R12010

4 JUNCTION BLOCK
FT
RA
D
DOIQH004R12011

JUNCTION BLOCK 4
FT
RA
D
DOIQH004R12012

4 JUNCTION BLOCK
FT
RA
D
DOIQH004R12013

JUNCTION BLOCK 4
FT
RA
D
DOIQH004R12014

4 JUNCTION BLOCK
FT
RA
D
DOIQH004R12015

JUNCTION BLOCK 4
FT
RA
D
DOIQH004R12016

4 JUNCTION BLOCK
ADVANCE BODY CONTROL MODULE (ABCM) CONNECTOR

Location of PIN SYMBOL on ADVANCE BODY CONTROL MODULE connector
FT
RA
D
DOIQH004R12017

JUNCTION BLOCK 4
FT
RA
D
DOIQH004R12018

4 JUNCTION BLOCK
/ 20 FUSIBLE LINK & FUSES
FUSIBLE LINK & FUSES WEW005CJUNC12001
( UEC Box in Engine compartment )
FT
RA
D
DOIQH005R12001

JUNCTION BLOCK 4
FUSIBLE LINK & FUSES / 21
FT
RA
DOIQH005R12002
D
No. Rated capacity Load Circuit

MF 01 100A Alternator
MF 02 80A Spare
JEF 1 40A Defogger, Power socket, CVT transmission
JEF 2 40A ABS
JEF 3 40A Spare
JEF 4 40A Spare
JEF 5 40A Cooling fan (HI) relay (K1)
JEF 6 40A Cooling fan (LO) relay (K2)
JEF 7 30A Blower relay (K3)
EF 1 25A ABS
EF 2 30A Starter relay (K4)
EF 3 15A Compressor PCB relay (K12)
EF 4 15A Fuel pump relay (K5)
EF 5 10A Recirculation pump relay (K13) <CFE>
EF 6 15A Front fog lamp relay (K6)
EF 7 10A HI beam (RH)
EF 8 10A HI beam (LH)
EF 9 15A LO beam (LH)

4 JUNCTION BLOCK
/ 22 FUSIBLE LINK & FUSES

EF 10 15A LO beam (RH)
EF 11 10A Position lamp (LH)
EF 12 10A Position lamp (RH)
EF 13 10A ECU
EF 14 15A Ignition coil
EF 15 15A Injector
EF 16 15A Sensors
FT
EF 17 10A Back-up lamp relay (K9)
EF 18 10A TCU
EF 19 10A ECU
EF 20 10A Headlamp levelling motor
EF 21 20A Spare
EF 22 10A Spare
EF 23 30A Spare
RA
EF 24 20A Spare
D

JUNCTION BLOCK 4
MULTI-PURPOSE FUSE / 23
MULTI-PURPOSE FUSE WEW005CJUNC12002
(Instrument panel electrical centre (IEC) Box in Driver’s compartment )
FT
RA
D
DOIQH005R12003

4 JUNCTION BLOCK
/ 24 MULTI-PURPOSE FUSE
FT
RA
DOIQH005R12004
D

F1 — Spare
F2 — Spare
F3 — Spare
F4 15A Front power socket
F5 15A Rear power socket
F6 10A Diagnosis
F7 20A BCM_defogger
F8 20A Audio / Cluster
F9 15A BCM_turn / Stop lamp
F 10 15A BCM
F 11 15A BCM_door lock
F 12 20A BCM_horn
F 13 10A BCM_battery saver
F 14 15A BCM_rear fog / OSRVM fold
F 15 10A Start stop button (SSB) switch
F 16 10A ACU
F 17 10A ABS
F 18 10A Cluster

JUNCTION BLOCK 4
MULTI-PURPOSE FUSE / 25

F 19 15A ECU / TCU / Gearshift
F 20 10A BCM / Cruise / KRA
F 21 10A Reverse sensor
F 22 10A HVAC
F 23 10A Relay coil
F 24 10A Front washer
F 25 20A Front wiper
FT
F 26 10A Gearshift solenoid
F 27 15A Audio
F 28 10A OSRVM
F 29 10A Starter
F 30 — Spare
F 31 — Spare
F 32 10A IGN1 OFF
RA
F 33 15A ACC
D

4 JUNCTION BLOCK
/ 26 RELAY
RELAY WEW005CJUNC12003
(Under hood electrical centre (UEC) Box in Engine compartment )
FT
RA
D
DOIQH005R12005
No. Relay name Connector No.

K1 Cooling fan (HI) relay A-17x
K2 Cooling fan (LO) relay A-18x
K3 Blower relay A-19x
K4 Starter relay A-20x
K5 Fuel pump relay A-21x
K6 Fog lamp relay A-22x
K7 Low beam relay A-23x
K8 Main relay A-24x
K9 Back-up lamp relay A-25x
K 10 Spare
K 11 Spare
K 12 Compressor relay
PCB relay (built in)
K 13 Recirculation pump relay (CFE)
K 14 High beam relay
K 15 Position lamp (Illumination) relay

JUNCTION BLOCK 4
RELAY / 27
(Instrument panel electrical centre (IEC) Box in Engine compartment )
FT
RA
D
DOIQH005R12006
No. Relay name Connector No.

K1 Power window relay C-09x
K2 Power socket relay C-10x
K3 Gearshift solenoid relay C-11x
K4 Spare
K5 Spare
PCB relay (built in)
K6 IGN 1 (OFF) relay
K7 ACC relay
K8 IGN 1 (ON) relay C-12x
K9 IGN 2 relay C-13x

4 JUNCTION BLOCK
/ 28 RELAY
NOTE
FT
RA
D

POWER UNIT 6
Content /1
6 POWER UNIT
POWER DISTRIBUTION SYSTEM ................................................... 6/2
POWER DISTRIBUTION SYSTEM (Continued) .................................. 6/3
STARTING SYSTEM ................................................................... 6/16
CHARGING SYSTEM ................................................................. 6/17
IGNITION SYSTEM .................................................................... 6/18
FT
IGNITION SYSTEM (Continued) ................................................... 6/19
IMMOBILISER SYSTEM .............................................................. 6/20
START AND STOP BUTTON .......................................................... 6/21

START AND STOP BUTTON (Continued) ........................................ 6/22
RA
D

6 POWER UNIT
/2 POWER DISTRIBUTION SYSTEM
POWER DISTRIBUTION SYSTEM WEW006POWER11014
FT
RA
D
DOIQH006R11001

POWER UNIT 6
POWER DISTRIBUTION SYSTEM /3
POWER DISTRIBUTION SYSTEM (Continued)
FT
RA
D
DOIQH006R11002

6 POWER UNIT
FT
RA
D
DOIQH006R11003

POWER UNIT 6
FT
RA
D
DOIQH006R11004

6 POWER UNIT
FT
RA
D
DOIQH006R11005

POWER UNIT 6
FT
RA
D
DOIQH006R11006

6 POWER UNIT
FT
RA
D
DOIQH006R11007

POWER UNIT 6
FT
RA
D
DOIQH006R11008

6 POWER UNIT
/ 10 POWER DISTRIBUTION SYSTEM
FT
RA
D
DOIQH006R11009

POWER UNIT 6
POWER DISTRIBUTION SYSTEM / 11
FT
RA
D
DOIQH006R11010

6 POWER UNIT
FT
RA
D
DOIQH006R11011

POWER UNIT 6
FT
RA
D
DOIQH006R11012

6 POWER UNIT
FT
RA
D
DOIQH006R11013

POWER UNIT 6
FT
RA
D
DOIQH006R11014

6 POWER UNIT
STARTING SYSTEM WEW006POWER11015
FT
RA
D
DOIQH006R11015

POWER UNIT 6
CHARGING SYSTEM WEW006POWER11016
FT
RA
D
DOIQH006R11016

6 POWER UNIT
IGNITION SYSTEM WEW006POWER11017
FT
RA
D
DOIQH006R11017

POWER UNIT 6
IGNITION SYSTEM (Continued)
FT
RA
D
DOIQH006R11018

6 POWER UNIT
/ 20 IMMOBILISER SYSTEM
IMMOBILISER SYSTEM WEW006POWER11018
FT
RA
D
DOIQH006R11019

POWER UNIT 6
START AND STOP BUTTON / 21
START AND STOP BUTTON WEW006POWER11019
FT
RA
D
DOIQH006R11020

6 POWER UNIT
/ 22 START AND STOP BUTTON
START AND STOP BUTTON (Continued)
FT
RA
D
DOIQH006R11021

ENGINE AND TRANSMISSION MANAGEMENT SYSTEM 7
Content /1
7 ENGINE AND TRANSMISSION MANAGEMENT SYSTEM

MPI SYSTEM <IAFM> ................................................................ 7/2
MPI SYSTEM <IAFM> (Continued) ............................................... 7/3
MPI SYSTEM <CFE> ................................................................... 7/9

MPI SYSTEM <CFE> (Continued) ................................................. 7/10
CONTINUOS VARIABLE TRANSMISSION <CVT> ................................. 7/17

CONTINUOS VARIABLE TRANSMISSION <CVT> (Continued) ............... 7/18
FT
COOLING SYSTEM .................................................................... 7/24
RA
D

/2 MPI SYSTEM <IAFM>
MPI SYSTEM <IAFM> WEW007EMSYS11013
FT
RA
D
DOIQH007R11001

MPI SYSTEM <IAFM> /3
MPI SYSTEM <IAFM> (Continued)
FT
RA
D
DOIQH007R11002

FT
RA
D
DOIQH007R11003

FT
RA
D
DOIQH007R11004

FT
RA
D
DOIQH007R11005

FT
RA
D
DOIQH007R11006

FT
RA
D
DOIQH007R11007

MPI SYSTEM <CFE> /9
MPI SYSTEM <CFE> WEW007EMSYS12001
FT
RA
D
DOIQH007R12001

/ 10 MPI SYSTEM <CFE>
MPI SYSTEM <CFE> (Continued)
FT
RA
D
DOIQH007R12002

MPI SYSTEM <CFE> / 11
FT
RA
D
DOIQH007R12003

FT
RA
D
DOIQH007R12004

FT
RA
D
DOIQH007R12005

FT
RA
D
DOIQH007R12006

FT
RA
D
DOIQH007R12007

FT
RA
D
DOIQH007R12008

CONTINUOS VARIABLE TRANSMISSION <CVT> / 17
CONTINUOS VARIABLE TRANSMISSION <CVT> WEW007EMSYS12002
FT
RA
D
DOIQH007R12010

/ 18 CONTINUOS VARIABLE TRANSMISSION <CVT>
CONTINUOS VARIABLE TRANSMISSION <CVT> (Continued)
FT
RA
D
DOIQH007R12011

FT
RA
D
DOIQH007R12012

FT
RA
D
DOIQH007R12013

FT
RA
D
DOIQH007R12014

FT
RA
D
DOIQH007R12015

FT
RA
D
DOIQH007R12016

/ 24 COOLING SYSTEM
COOLING SYSTEM WEW007EMSYS12003
FT
RA
D
DOIQH007R12017

EXTERIOR LIGHTING 8
Content /1
8 EXTERIOR LIGHTING
HEADLAMP ............................................................................. 8/2
HEADLAMP LEVELING SYSTEM .................................................... 8/3
FRONT FOG LAMP .................................................................... 8/4

OPERATION .......................................................................... 8/5
TROUBLESHOOTING HINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/5
REAR FOG LAMP ..................................................................... 8/6
FT
OPERATION .......................................................................... 8/7
TROUBLESHOOTING HINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/7
TAIL LAMP, LICENCE LAMP, POSITION LAMP & ILLUMINATION LAMP ...... 8/8
TAIL LAMP, LICENCE LAMP, POSITION LAMP & ILLUMINATION LAMP 8/9
(Continued) ..........................................................................
STOP LAMP ............................................................................. 8/10

RA
STOP LAMP (Continued) ........................................................... 8/11
TURN SIGNAL LAMP & HAZARD LAMP .......................................... 8/12

TURN SIGNAL LAMP & HAZARD LAMP (Continued) ......................... 8/13
OPERATION .......................................................................... 8/14
[Turn-signal lamp] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/14
[Hazard lamp] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8/14
TROUBLESHOOTING HINTS ....................................................... 8/14
BACK-UP LAMP & REVERSE SENSOR .............................................. 8/15

D
HORN .................................................................................... 8/16

8 EXTERIOR LIGHTING
/2 HEADLAMP
HEADLAMP WEW008XRIOR11025
FT
RA
D
DOIQH008R11001

EXTERIOR LIGHTING 8
HEADLAMP LEVELING SYSTEM /3
HEADLAMP LEVELING SYSTEM WEW008XRIOR11032
FT
RA
D
DOIQH008R11002

8 EXTERIOR LIGHTING
/4 FRONT FOG LAMP
FRONT FOG LAMP WEW008XRIOR11026
FT
RA
D
DOIQH008R11003

EXTERIOR LIGHTING 8
FRONT FOG LAMP /5
OPERATION
Front fog lamp Relay “ON” Conditions
Lighting switch Ignition switch Front fog lamp relay

“TAIL” ON ON
• If ignition is ON and position lamp is ON, front fog lamp is turned ON when front fog lamp switch
is pressed.
• Fog lamp will be turned OFF, if fog lamp switch is pressed again.
• If ignition is OFF or position lamp is OFF, fog lamp will be OFF.
FT
TROUBLESHOOTING HINTS
1. The front fog lamp doesn't illuminate.
(1) Tail lamps go “ON”.
• Check fuse No. (15A) in UEC box.
• Check front fog lamp relay.
• Check front fog lamp switch.
• Check BCM connector for proper connection.
2. The front fog lamp at one side doesn't illuminate.
RA
• Check the lamp bulb.
D

8 EXTERIOR LIGHTING
/6 REAR FOG LAMP
REAR FOG LAMP WEW008XRIOR11033
FT
RA
D
DOIQH008R11004

EXTERIOR LIGHTING 8
REAR FOG LAMP /7
OPERATION
Front fog lamp Relay “ON” Conditions
Lighting switch Ignition switch Front fog lamp relay

“TAIL” ON ON
• If ignition is ON and position lamp is ON, front fog lamp is turned ON when front fog lamp switch
is pressed.
• Fog lamp will be turned OFF, if fog lamp switch is pressed again.
• If ignition is OFF or position lamp is OFF, fog lamp will be OFF.
FT
1. The front fog lamp doesn't illuminate.
(1) Tail lamps go “ON”.
• Check fuse No.1 (40A) in UEC box.
• Check front fog lamp relay.
• Check front fog lamp switch.
2. The front fog lamp at one side doesn't illuminate.
RA
D

8 EXTERIOR LIGHTING
/8 TAIL LAMP, LICENCE LAMP, POSITION LAMP & ILLUMINATION LAMP
TAIL LAMP, LICENCE LAMP, POSITION LAMP & ILLUMINATION LAMP

WEW008XRIOR11027
FT
RA
D
DOIQH008R11005

EXTERIOR LIGHTING 8
TAIL LAMP, LICENCE LAMP, POSITION LAMP & ILLUMINATION LAMP /9
TAIL LAMP, LICENCE LAMP, POSITION LAMP & ILLUMINATION LAMP (Continued)
FT
RA
D
DOIQH008R11006

8 EXTERIOR LIGHTING
/ 10 STOP LAMP
STOP LAMP WEW008XRIOR11028
FT
RA
D
DOIQH008R11007

EXTERIOR LIGHTING 8
STOP LAMP / 11
STOP LAMP (Continued)
FT
RA
D
DOIQH008R11008

8 EXTERIOR LIGHTING
/ 12 TURN SIGNAL LAMP & HAZARD LAMP
TURN SIGNAL LAMP & HAZARD LAMP WEW008XRIOR11029
FT
RA
D
DOIQH008R11009

EXTERIOR LIGHTING 8
TURN SIGNAL LAMP & HAZARD LAMP / 13
TURN SIGNAL LAMP & HAZARD LAMP (Continued)
FT
RA
D
DOIQH008R11010

8 EXTERIOR LIGHTING
/ 14 TURN SIGNAL LAMP & HAZARD LAMP
OPERATION
The flasher fuctionality generates all the signals to drive the turn indicator lamp in response to internal
or external request. These signals are a succession of ON and OFF states.
Internal request come from hardware inputs: Left turn switch, Right turn switch along with the ignition
status (Turn signal mode) and Hazard switch (Hazard mode).
External request comes from other fuctionalities: CDL (crash air bag), Alarm mode, and monitoring
the vehicle speed in order to perform hazard on heavy brake (HOD mode).
[Turn-signal lamp]
1. In normal operating condition
FT
• When the ignition switch is placed in the “ON” position, battery voltage is applied through the
fuse No. 14 (10A) IEC Box and hazard switch to the turn-signal and hazard flasher unit.
• When the turn signal switch is turned to the “LH” or “RH” position, the relay contact turns “ON”
and “OFF” repeatedly due to the switching operation of the condenser and transistor inside the
flasher unit, and the turn signal lamp and the “LH” or “RH” of the turn signal indicator lamp
flash.
2. When one bulb is burnt
• When either one of the turn signal lamps is burnt, the resistance of the entire lamp circuit in-
RA
creases, so that the time required for charging and discharging of the condenser is shortened,
causing the “ON” “OFF” cycle of the relay to become faster than normal and the number of
flasher to increase.
[Hazard lamp]
• The flasher shall perform hazard sequence if hazard switch is ON or crash signal is received. Hazard
sequence by hazard switch shall be stopped by press hazard switch again. Hazard sequence by crash
shall be stopped by press hazard switch. Hazard mode sequence is the same as turn signal mode se-
quence.
REMARK
D
• The number of times the lamps flash on and off does not change even when one bulb is out.
1. Neither the turn-signal lamps nor hazard lamps operate.
• Check hazard switch contacts (on power source end).
• Check flasher unit.
• Check the BCM connector for proper connection.
2. All LH or RH turn-signal lamps do not operate.
(1) Hazard lamp is fully operational.
• Check PF fuse No.22 (10A)
• Check turn-signal switch.
• Check the BCM connector for proper connection.
3. Flashing cycle of turn signal lamps is shorter.
4. Hazard lamp does not operate.
(1) Turn-signal lamps are operational.
• Check PF fuse No.14 (10A)
• Check hazard switch contacts (on hazard lamp end).

EXTERIOR LIGHTING 8
BACK-UP LAMP & REVERSE SENSOR / 15
BACK-UP LAMP & REVERSE SENSOR WEW008XRIOR11030
FT
RA
D
DOIQH008R11011

8 EXTERIOR LIGHTING
/ 16 HORN
HORN WEW008XRIOR11031
FT
RA
D
DOIQH008R11012

INTERIOR LIGHTING 9
Content /1
9 INTERIOR LIGHTING
INTERIOR LAMP AND LUGGAGE COMPARTMENT LAMP ..................... 9/2
INTERIOR LAMP AND LUGGAGE COMPARTMENT LAMP (Continued) ... 9/3
OPERATION .......................................................................... 9/4
FT
RA
D

9 INTERIOR LIGHTING
/2 INTERIOR LAMP AND LUGGAGE COMPARTMENT LAMP
INTERIOR LAMP AND LUGGAGE COMPARTMENT LAMP WEW009INTER11006
FT
RA
D
DOIQH009R11001

INTERIOR LIGHTING 9
INTERIOR LAMP AND LUGGAGE COMPARTMENT LAMP /3
INTERIOR LAMP AND LUGGAGE COMPARTMENT LAMP (Continued)
FT
RA
D
DOIQH009R11002

9 INTERIOR LIGHTING
/4 INTERIOR LAMP AND LUGGAGE COMPARTMENT LAMP
OPERATION
• The interior lighting fuctionality is split in 2 sub-functions:
1) Control of the interior lights.
2) Control battery saver relay.
• Interior lights control sub-function takes care of the activation / deactivation of the interior lights.
• There are 1 room lamps (8W), 1 map lamps (10W) and key illumination (1.5W) controlled by BCM
interior light control.
• Battery saver control sub-function takes care of the activation / deactivation of the battery saver
relay.
• The interior light fades in when either of following condition is meet:
FT
1) Any door is opened.
2) Ignition is switch OFF.
3) Unlock demand occurs while ignition switch is in OFF position.
• The interior light fades out when either of following condition is met:
1) Ignition is switch ON and all doors are closed.
2) Lock demand (either remote or local request) occurs, while ignition switch is in OFF position and
all doors are closed.
3) 30 second has elapsed since the last door was closed (while the car is not centrally lock).
RA
4) 30 second has elapsed since the interior light was turned on which ever occurs last.
5) The last door is closed while the car is centrally locked.
• The interior light is immediately switched OFF when 15 minutes has elapsed since the last restart of
the battery saver timer.
1. Room lamp does not come on.
(1) Luggage lamp is not “ON”, either.
• Check PF Fuse No.17 (10A) in PF box.
D
• Check PF Fuse No.14 (10A) in PF box.

(2) Room lamp or MAP lamp does not come on when any door is opened with the room lamp
switch in the “DOOR” position.
• Check bulb.
• Check room lamp switch.
2. Luggage compartment lamp does not come on.
(1) Room lamp is normal.
• Check bulb.
• Check luggage compartment lamp switch.

DRIVER INFORMATION 10
Content /1
10 DRIVER INFORMATION
METER AND GAUGE .................................................................. 10/2
METER AND GAUGE (Continued) ................................................ 10/3
OPERATION .......................................................................... 10/7
<Temperature gauge> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/7
<Fuel gauge> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/7
OIL PRESSURE, SEAT BELT, BRAKE AND FUEL WARNING LAMP ............. 10/8
OIL PRESSURE, SEAT BELT, BRAKE AND FUEL WARNING LAMP ........... 10/9
OPERATION .......................................................................... 10/10
FT
<Oil pressure warning lamp> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/10
<Seat belt warning lamp> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/10
<Brake warning lamp> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/10
<Fuel warning lamp> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10/10
RA
D

/2 METER AND GAUGE
METER AND GAUGE WEW010DINFO11006
FT
RA
D
DOIQH010R11001

METER AND GAUGE /3
METER AND GAUGE (Continued)
FT
RA
D
DOIQH010R11002

/4 METER AND GAUGE
FT
RA
D
DOIQH010R11003

METER AND GAUGE /5
FT
RA
D
DOIQH010R11004

/6 METER AND GAUGE
FT
RA
D
DOIQH010R11005

METER AND GAUGE /7
OPERATION
<Temperature gauge>
• When the ignition switch is at the “ON” position, the engine coolant temperature gauge is activated.
• When the engine coolant temperature is high, the unit's resistance is low and there is a great flow
of current in the circuit, so the gauge's indicator indicates in the “H” area.
• When the engine coolant temperature is low, the unit's resistance is high and there is a small flow
of current in the circuit, so the gauge's indicator indicates in the “C” area.
<Fuel gauge>
FT
• When the ignition switch is at the “ON” position, the fuel gauge temperature gauge is activated.
• When there is much fuel, the unit's resistance is small and current flowing in the curcuit is high, so
the gauge's indicator indicate in the “F” area.
• When there is little fuel, the unit's resistance is high and the current flowing in the curcuit is small,
so the gauge's indicator indicates in the “E” area.
RA
D

/8 OIL PRESSURE, SEAT BELT, BRAKE AND FUEL WARNING LAMP
OIL PRESSURE, SEAT BELT, BRAKE AND FUEL WARNING LAMP WEW010DINFO11007
FT
RA
D
DOIMH010R07003

OIL PRESSURE, SEAT BELT, BRAKE AND FUEL WARNING LAMP /9
OIL PRESSURE, SEAT BELT, BRAKE AND FUEL WARNING LAMP
FT
RA
D
DOIMH010R07004

/ 10 OIL PRESSURE, SEAT BELT, BRAKE AND FUEL WARNING LAMP
OPERATION
<Oil pressure warning lamp>
• When the lubrication system fails after engine starting, resulting in the oil pressure failing to build
up, the oil pressure switch turns “ON” causing the oil pressure warning lamp to light up.
<Seat belt warning lamp>
• When the seat belt is fastened with the ignition switch set at the “ON” position, the buckle switch
is turned off to unlight the seat belt warning lamp.
<Brake warning lamp>
FT
• When the brake fluid level goes down below a predetermined level or parking brake lever is pulled,
with the ignition switch in the “ON” position, the brake fluid level is activated or the parking brake
switch is turned “ON”, causing the brake warning lamp to light up.
<Fuel warning lamp>
• When the fuel level goes down causing the fuel gauge resistance is high and current flowing in the
circuit is small, with the ignition switch in the “ON” position current flow to the “IC” and lights up
the fuel warning lamp to warn the driver that the the amount of fuel still available for use is small.
RA
D

WIPE AND WASH 11
Content /1
11 WIPE AND WASH

WINDSHIELD WIPER AND WASHER ............................................... 11/2
WINDSHIELD WIPER AND WASHER (Continued) ............................. 11/3
OPERATION .......................................................................... 11/4
<Front wiping (High/Low speed) control> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/4
<Front wiping intermittent control> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/4
<Dwell-time programming> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/4
<Front wash wiping> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/4
<Prolongation wiping> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/4
<Drip wiping> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/4
FT
RA TROUBLESHOOTING HINTS ....................................................... 11/4
D

11 WIPE AND WASH
/2 WINDSHIELD WIPER AND WASHER
WINDSHIELD WIPER AND WASHER WEW011WWASH11006
FT
RA
D
DOIQH011R11001

WIPE AND WASH 11
WINDSHIELD WIPER AND WASHER /3
WINDSHIELD WIPER AND WASHER (Continued)
FT
RA
D
DOIQH011R12001

11 WIPE AND WASH
OPERATION
• The front wiper activity is enabled after the ignition is switched ON. If ignition is switched OFF, the
complete wiper function returns to the default state and the wiper outputs are switched OFF. It is
configurable in BCM non-volatile memory.
• There are several different kinds of activities: OFF, Intermittent mode (user programing dwell time),
Wash mode, Drip wipe and continue (slow / high speed) mode.
• While vehicle is moving with front wiper at low speed, when vehicle comes to 0 km/h speed, wiper
will switch to intermittent mode automatically, when speed is up, front wiper will return to low speed
again.
FT
<Front wiping (High/Low speed) control>
• When the front wiper handle is moved to high position, the front wiper moves as high speed imme-
diately.
• When the front wiper handle is moved to low position, the front wiper moves as low speed imme-
diately.
<Front wiping intermittent control>
• When the front wiper handle is moved to intermittent mode, the wiper will be activated immediately
RA
in intermittent mode (beginning with a wipe cycle, and then stop in dwell time).
• The wiper motor will only be activated when ignition switch is ON.
<Dwell-time programming>
• Front wiper Dwell time can be user programmable via front wiper switch.
<Front wash wiping>
• Front wash wiping has 3 modes:
1) Wash wiping.
2) Prolongation wiping.
3) Drip wiping mode.
D
• When the front washer is press ON for 15 seconds, the front wipe will be stopped immediately and
then with a drip wipe.
• When the front wiper handle is in OFF position, then press Front washer switch, the washing mode
is activated, after 280ms, the wiper is activated in slow speed.
• During washing mode, the front wiper motor is activated continuously in slow speed.
• When the front wiper handle in OFF position, press front wiper switch, the front wiper motor must
remain activated the whole time the front washer switch is being pressed.
<Prolongation wiping>
• When front wiper handle in OFF position, press front washer switch, when the front washer switch
is released the front wiper motor will remain activated for another 3 complete wipe cycle, and then
it will stop in park position.
• For the last prolongation wipe cycle the wiper motor will be activated for only 480ms, then the relay
will be turned off, and the front wiper motor will reach park position by it self.
<Drip wiping>
• When front washer switch pressed, and front wiper motor activated in continuous slow speed.
• After releasing the front washer switch the prolongation wipes are performed. From the moment
the last prolongation wipe is complete (front wiper reaches park position and stops), there will be an
interval of 5s before the front wiper is again activated for a single wipe.
1. Wipers do not operate.
(1) Washer is not operative, either
• Check fuse No.15 (20A),fuse No.24 (10A) at UEC fuse box.

WIPE AND WASH 11
WINDSHIELD WIPER AND WASHER /5

2. Low-speed (or high speed) wiper operation only is inoperative.
• Check wiper switch.
3. Wiper do not stop.
• Check wiper motor.
• Check wiper switch.
4. Washer is inoperative.
(1) Wiper is operative on washer-wiper operation.
FT
• Check washer motor.
(2) Washer-wiper operation is inoperative also.
• Check washer switch.
RA
D

11 WIPE AND WASH
NOTE
FT
RA
D

ASSISTANT MECHANISM 12
Content /1
12 ASSISTANT MECHANISM
SRS ....................................................................................... 12/2
SRS (Continued) ..................................................................... 12/3
AUTO CRUISE .......................................................................... 12/5

OPERATION .......................................................................... 12/6
POWER WINDOW ..................................................................... 12/7
FT
POWER WINDOW <Continued> ................................................. 12/8
OPERATION .......................................................................... 12/10
CENTRAL DOOR LOCK ............................................................... 12/11

CENTRAL DOOR LOCK (Continued) ............................................. 12/12
OPERATION .......................................................................... 12/13
Driver door only unlock and switching with remoote key lock or un- 12/13
lock. ....................................................................................
RA
REMOTE CONTROLLED MIRROR ................................................... 12/14

REMOTE CONTROLLED MIRROR (Continued) ................................. 12/15
D

/2 SRS
SRS WEW012AMECH11014
FT
RA
D
DOIQH012R11001

SRS /3
SRS (Continued)
FT
RA
D
DOIQH012R11002

/4 SRS
SRS (Continued)
FT
RA
D
DOIQH012R11003

AUTO CRUISE /5
AUTO CRUISE WEW012AMECH11015
FT
RA
D
DOIQH012R11004

/6 AUTO CRUISE
OPERATION
• The cruise control function is to set up a constant speed of car set by users.
• It enables the car to move at the setting speed without pressing accelerator pedal.
• There are 4 switches integrated with control switch, which are main, coast, set and cancel. Each
of them has its own function.
1. Auto-cruise control cannot be set.
• Check PF fuse No.12 (10A) at panel fuse box.
• Check PF fuse No.16 (10A) at panel fuse box.
FT
• Check Auto-cruise switch.
2. Auto-cruise control cannot be cancelled.
• Check stop lamp switch.
• Check ECU unit.
3. Auto-cruise indicator lamp does not illuminate.
• Check bulb.
RA
D

POWER WINDOW /7
POWER WINDOW WEW012AMECH11016
FT
RA
D
DOIQH012R11005

/8 POWER WINDOW
POWER WINDOW <Continued>
FT
RA
D
DOIQH012R11006

POWER WINDOW /9
POWER WINDOW <Continued>
FT
RA
D
DOIQH012R11007

/ 10 POWER WINDOW
OPERATION
• When the power window (main or sub) switch is depressed, (UP or DOWN) with the ignition switch
in the “ON” position, current flows to the power window motor. This energized the power window
motor causing the door window glass to open or close.
• When the DOWN side of the power window main switch (driver's seat side switch) is depressed all
the way, it is locked in the depressed position and the power window motor is operated until the
door glass is fully opened.
• When the power window lock switch is placed in the “LOCK (OFF)” position, operating a switch
other than the ones for the driver's side does not cause the power window motor to be operated.
• The power window motor is provided with a circuit breaker that protects the motor from damage
FT
caused by over current.
1. All door glasses cannot be opened or closed.
• Check PF fuse No. 27 (10A) in PF fuse box.
• Check Fusible link fuse No. 8 (30A) in EJB box.
• Check power window relay.
RA
• Check power window main switch.
2. Some door glass cannot be opened or closed.
(1) Neither power window main nor sub switch is activated.
• Check power window main switch.
• Check defective power window motor.
(2) Either power window main or sub switch is inoperative.
• Check inoperative power window switch.
D
3. One-touch switch function is not operational.

• Replace power window main switch.

CENTRAL DOOR LOCK / 11
CENTRAL DOOR LOCK WEW012AMECH11017
FT
RA
D
DOIQH012R11008

/ 12 CENTRAL DOOR LOCK
CENTRAL DOOR LOCK (Continued)
FT
RA
D
DOIQH012R11009

CENTRAL DOOR LOCK / 13
OPERATION
When central lock button is pressed or key in key cylinder is turned to lock positon, if both front left
door and front right door are closed, all 4 doors are locked. If either front left door or front right
door is ajar, all 4 doors are reverse unlock. After central lock, the interior light will be off with fade
out.
When central unlock button is pressed or key in key in key cylinder is turned to unlock position, all 4
doors are unlocked so they can be opened from the outside or the inside of the vehicle. Interior
central unlock can be executed only when vehicle is in disarmed state. After central unlock, the interior
light will be on with fade in.
FT
Driver door only unlock and switching with remoote key lock or unlock.
IF current central door locking (CDL) unlocking mode is driver door unlock (DDU), and the doors are
locked, after first central unlock request, the driver door will be unlocked while other 3 doors are still
lock.
After second central unlock request other 3 door will be central unlocked.
Press down the remootetransmitter lock and unlock buttons in the same time for 200ms will toggle
CDU and DDU mode. The flasher will work for 2 times for acknowledgement.
RA
1. Any one of the door actuators is inoperative.
• Check the defective door actuator.
2. Door cannot be locked or unlocked with the inside lock knob on the driver’s seat (including key
operation).
• Check PF fuse No.14 (10A) in panel fuse box.
• Check door latch switch.
• Check BCM connector for proper connection..
D

/ 14 REMOTE CONTROLLED MIRROR
REMOTE CONTROLLED MIRROR WEW012AMECH11018
FT
RA
D
DOIQH012R11010

REMOTE CONTROLLED MIRROR / 15
REMOTE CONTROLLED MIRROR (Continued)
FT
RA
D
DOIQH012R12001

/ 16 REMOTE CONTROLLED MIRROR
NOTE
FT
RA
D

DRIVER AIDS 13
Content /1
13 DRIVER AIDS
ABS with ESP .......................................................................... 13/2
ABS with ESP (Continued) ......................................................... 13/3
FT
RA
D

13 DRIVER AIDS
/2 ABS with ESP
ABS with ESP WEW013DAIDS11006
FT
RA
D
DOIQH013R12001

DRIVER AIDS 13
ABS with ESP /3
ABS with ESP (Continued)
FT
RA
D
DOIQH013R12002

13 DRIVER AIDS
/4 ABS with ESP
FT
RA
D
DOIQH013R12003

DRIVER AIDS 13
ABS with ESP /5
FT
RA
D
DOIQH013R12004

13 DRIVER AIDS
/6 ABS with ESP
NOTE
FT
RA
D

DRIVING COMFORT 14
Content /1
14 DRIVING COMFORT
RADIO – HI LINE ....................................................................... 14/2
RADIO – LO LINE ...................................................................... 14/3
DEFOGGER ............................................................................. 14/4
POWER SOCKET ....................................................................... 14/5
ALARM SYSTEM ....................................................................... 14/6
FT
ALARM SYSTEM (Continued) ..................................................... 14/7
HEATER, VENTILATION AND AIR-COND SYSTEM ............................... 14/8

HEATER, VENTILATION AND AIR-COND SYSTEM (Continued) ............. 14/9
CLOCK ................................................................................... 14/11

RA
D

14 DRIVING COMFORT
/2 RADIO – HI LINE
RADIO – HI LINE WEW014DCOMF11018
FT
RA
D
DOIQH014R11001

DRIVING COMFORT 14
RADIO – LO LINE /3
RADIO – LO LINE WEW014DCOMF11024
FT
RA
D
DOIQH014R11002

14 DRIVING COMFORT
/4 DEFOGGER
DEFOGGER WEW014DCOMF11019
FT
RA
D
DOIQH014R11003

DRIVING COMFORT 14
POWER SOCKET /5
POWER SOCKET WEW014DCOMF11020
FT
RA
D
DOIQH014R11004

14 DRIVING COMFORT
/6 ALARM SYSTEM
ALARM SYSTEM WEW014DCOMF11021
FT
RA
D
DOIQH014R11005

DRIVING COMFORT 14
ALARM SYSTEM /7
ALARM SYSTEM (Continued)
FT
RA
D
DOIQH014R12001

14 DRIVING COMFORT
/8 HEATER, VENTILATION AND AIR-COND SYSTEM
HEATER, VENTILATION AND AIR-COND SYSTEM WEW014DCOMF11022
FT
RA
D
DOIQH014R12002

DRIVING COMFORT 14
HEATER, VENTILATION AND AIR-COND SYSTEM /9
HEATER, VENTILATION AND AIR-COND SYSTEM (Continued)
FT
RA
D
DOIQH014R12003

14 DRIVING COMFORT
/ 10 HEATER, VENTILATION AND AIR-COND SYSTEM
HEATER, VENTILATION AND AIR-COND SYSTEM (Continued)
FT
RA
D
DOIQH014R12004

DRIVING COMFORT 14
CLOCK / 11
CLOCK WEW014DCOMF11023
FT
RA
D
DOINH014R09006

14 DRIVING COMFORT
/ 12 CLOCK
NOTE
FT
RA
D

WORKSHOP MANUAL
FLAT RATES
CR
Model YR 2009
Destination: ALL
Copyright ©
Perusahaan Otomobil
Nasional Sdn. Bhd.
WORKSHOP MANUAL ALL
Group Index /I
00 GENERAL ................................................................................... 00/1 - 00/11

11 ENGINE ...................................................................................... 11/1 - 11/10
12 LUBRICATION ............................................................................... 12/1 - 12/3
13 FUEL ............................................................................................ 13/1 - 13/7
14 COOLING ..................................................................................... 14/1 - 14/6
15 INTAKE AND EXHAUST ................................................................. 15/1 - 15/5
16 ENGINE ELECTRICAL ..................................................................... 16/1 - 16/5
17 EMISSION CONTROL ..................................................................... 17/1 - 17/4
21 CLUTCH ....................................................................................... 21/1 - 21/3
22 MANUAL TRANSMISSION ............................................................. 22/1 - 22/7
23 TRANSMISSION (CVT) ................................................................... 23/1 - 23/7
26 FRONT AXLE ................................................................................ 26/1 - 26/3
27 REAR AXLE .................................................................................. 27/1 - 27/3
31 WHEEL AND TYRE ........................................................................ 31/1 - 31/3
32 POWER PLANT MOUNT ................................................................ 32/1 - 32/3
33 FRONT SUSPENSION ..................................................................... 33/1 - 33/3
34 REAR SUSPENSION ....................................................................... 34/1 - 34/3
35 SERVICE B AKE ............................................................................ 35/1 - 35/7
36 PARKING BRAKE ........................................................................... 36/1 - 36/3
37 STEERING ..................................................................................... 37/1 - 37/5
42 BO Y (PARTS) ............................................................................ 42/1 - 42/11
42A BO Y PAINT ............................................................................ 42A/1 - 42A/5
51 EXTERIOR .................................................................................... 51/1 - 51/7
52 INTERIOR ................................................................................... 52/1 - 52/12
54 CHASSIS ELECTRICAL .................................................................. 54/1 - 54/10
55 HEATER, AIR CONDITIONER AND VENTILATION ............................. 55/1 - 55/7
100 WORK CODE TABLE .................................................................. 100/1 - 100/2
102 FAILURE CODE .......................................................................... 102/1 - 102/8
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.

GENERAL 00
Content /1
00 GENERAL
FOREWORD ............................................................................ 00/2
GENERAL ................................................................................ 00/2

USING THE MANUAL ............................................................... 00/2
EXPLANATION OF OPERATION CODE ........................................... ......00/2
HOW TO SELECT A PROPER OPERATION CODE ................................. ......00/3
EXPLANATION OF FAILURE CODE ............................................... ......00/3
HOW TO SELECT A FAILURE CODE .............................................. ......00/3
FLAT RATE TIME ................................................................. ......00/4
HOW TO READ FLAT RATE TIME TABLE .......................................... 00/5
GRAPHIC ILLUSTRATIONS ........................................................... 00/8
APPLICABLE VEHICLE MODEL ...................................................... 00/10

ENGINE AND TRANSMISSION MODELS AND THEIR ABBREVIATION ......00/10
DEFINITION OF TERMS ............................................................. 00/11

0 GENERAL
/2 FOREWORD
FOREWORD FRM000FWORD11008
This Flat Rate Manual is prepared for service personnel authorized by PROTON therefore can be used
as a handbook for estimating repair costs and handling warranty claims correctly and efficiently.
The operation times listed in this manual should be successfully achieved by a technician with three
(3) years or more experience in servicing/repairing motor vehicles using the specified part and special
tools in the correct environment.
It is your duty, as repairer, to ensure that any PROTON vehicle is serviced correctly, efficiently and safely
in accordance with good workshop practices.
All flat rate times listed herein are subject to the changes at any time by PRO ON SDN BHD based on
time studies related to design change, enhancement or improvement of repair methods, techniques or
equipment, or other advance in the industry.
NOTE:
PLEASE PAY EXTRA CAREFUL ATTENTION TO THE IN ORMATION IN THIS MANUAL, PROPERLY
AND CORRECTLY USE THE INFORMATION WILL PROVE TO BE AN INVALUABLE AID FOR
PROPERLY HANDLING WARRANTY CLAIMS AND IN ACCURATELY ESTIMATING REPAIR COST.
GENERAL FRM000GINFO11001
USING THE MANUAL

Notes on using this manual are included below. Please pay careful attention to them. Using this manual
correctly will help you with the accurate completion of your warranty service claims and submission of
any repair cost estimates.
EXPLANATION OF OPE ATION CODE
OPERATION CODE
There are two types of operation codes: the operation code for the main operation and the operation
code for any additional operation
1. Operation code for the main operation
The operation code for the main operation is composed of a combination of the position code
(consisting of six digits) and the work code (consisting of two digits).
The position code indicates the Group to which the part is belongs; the first two digits are the major
group, the second two digits are the medium group, and the third two digits are the minor group.
DOIIF000R9001
Symbol Description
1 Position code
2 Work code

GENERAL 00
FOREWORD /3
Symbol Description
3 Major group
4 Medium group
5 Minor group
For additional detail, refer to the “POSITION CODE INDEX” at the end of this manual.
The work code indicated the type of work i.e. replacement, repair, adjustment etc. For additional
details, refer to the 'WORK CODE INDEX' at the end of the Flat Rate manual.
1. Operation codes for any additional work
For operations where there is a high degree of probability that they will be performed simultan-eously
with the main operation, these are shown after the main operation. hese additional op-eration are
shown by codes as A1, A2, A3 etc.
HOW TO SELECT A PROPER OPERATION CODE
1. The POSITION CODE INDEX has been prepared to aid the selection of operation code. Please
utilise the POSITION CODE INDEX, particularly if you are experiencing a problem finding an
appropriate code
2. The page number following the position code will guide the reader to the appropriate page in the
manual. The lack of a page number in the POSITION CODE INDEX suggests that there is no
operation code in this manual
3. If an appropriate operation code cannot be found, then prepare a code using the following pro-
cedure:-.
a. Search the POSITION CODE INDEX for a suitable code. If an appropriate position code is found,
then completed the operation code by annexing the work code “99 (others)” to that position code
b. If you are unable to find a position code that is specific to the part that has failed, then use a
position code major group and medium group which is the next nearest and substitute “00” to the
minor group.
c. If you are unable to fine a position code that is close to the item requiring repair/replacement,
then use the correct major followed by medium group of “00” and a minor of “00”.
d. Whenever an appropriate work code is not found in the WORK CODE TABLE then use “99”
(others) for the work code
EXPLANATION OF FAILURE CO E
Failure codes are in three parts, and A code, B code and C code which are defined as follows:
1. A CODE
The A CODE is made up of two digits and it explains the failure condition of the original part which
failed (i.e. cracked, damaged or broken or seized etc.)
2. B CODE
The B CODE is made up of a two digit and it explains the symptoms leading up to or at the time the
defect occurred (e.g “poor startabillity”, “excessive oil consumption” etc.)
3. C CODE
The C CODE explains the conditions or circumstances at the time of failure (e.g when starting en-
gine, bad road conditions, when braking etc.)
HOW TO SELECT A FAILURE CODE
1. Failure codes A , B and C most appropriate for the operation codes can be refered to Module 7.12
(CODE AND INDEX)
2. Should you be unable to find an appropriate operation code then select failure code A and B from the
page which shown the first four digits ( major group and medium group ) of the operation code
applicable.
3. Should you be unable to find failure codes A and B then use “99 (others)”.

0 GENERAL
/4 FOREWORD
4. Wherever suitable failure codes A and B cannot be found and “99” has been used, then a full
description of complaint, cause and rectification must be entered in the remarks box of the warranty
service claim.
5. Select the most appropriate failure code C by referring to Module 7.12 under section “FAILURE
CODE TABLE”.
FLAT RATE TIME
The flat rate times shown throughout the text include all of the time required to complete a specific
operation, including time for inspection, adjustment, removal and installation of related parts, and a
confirmation test after the operation has been completed.
The time units shown in this manual are in tenths (1/10) of an hour. hus, 0.1 signifies 6 minutes, 0.2
signifies 12 minutes, 1.0 signifies 1 hour and 2.5 signifies 2 hours and 30 minutes

GENERAL 00
HOW TO READ FLAT RATE TIME TABLE /5
HOW TO READ FLAT RATE TIME TABLE FRM000HREAD11001
GENERAL
DOIIF000R9005
Symbol Description
1 Operation code
2 Name of main operation
3 The operations which are included in the main operation.
4 Times which occur as the result of the installation of additional components, the column
shows the flat rate times to be added. when such notations are shown, these times must
be added to the time for main operation. If, however the minus (-) is shown the times
should be subtracted from the time for the main operation
5 Vehicle model
6 Data shown in this column is the flat rate time of the main operation
7 Operation which may be required at the same time as the main operation. The times
shown in this column can be added to the time for the main operation.

0 GENERAL
/6 HOW TO READ FLAT RATE TIME TABLE
DOIIF000R9002
Example
When the clutch cover assembly and clutch release bearing are replaced at the same time, the flat rate
time is:
CLUTCH ISC ... REPLACEMENT ............. 3.0
Additional operation
Replace, release bearing........ 0.1
Flat rate time.......................... 3.1
Example
When an engine assembly replacement is carried out on a model equipped with related engine, the flat
rate times are as follows:-
CRANKSHAFT SPROCKET 1.8

Additional time allowance.
Air conditioner 0.3

Flat rate time 2.1
GROUP WORK FOR TRANSMISSION
The internal parts (including some others parts) related to the overhaul of transmission are arranged into
Group A, Group B, Group C etc. If a part or parts in Group A are repaired or replaced during an overhaul
of the transmission, this operation is then known as Group Work (A) etc.

GENERAL 00
HOW TO READ FLAT RATE TIME TABLE /7
In the same way operations conducted on a parts in Group (B), Group (C), are then known as Group
Work (B) , Group Work (C)...., respectively. If any part or parts are not shown in the illustration, de-
termine the Group using the Group known to contain adjacent parts.
The flat rate time is regardless of the number of parts repaired or replaced in any one Group since the flat
rate time for the Group Work is set taking into consideration the most time consuming oper-ation in the
group.
To obtain the flat rate time for simultaneous repair or replacement of more than one part in different
groups, during transmission overhaul, then the flat rate times of “T/M ASSY... OVERHAUL” should be
applied.
Example 1
What operation code and flat rate times are applicable to the replacement of the front and rear
bearings on the shaft of manual transmission?
Step 1
First, refer to the illustration. The front and rear bearings on the input shaft belong to Group D and their
replacement is therefore covered in Group Work (D).
Step 2
Then, check the flat rate time table page on Transmission Group Work (D) to see that the flat rate times
for manual Transmission is as below.
T/M GROUP WORK (H)............. 4.5
The operation code is 222010 9D
Example 2
What operation code and flat rate times are applicable to the replacement of the input shaft 3rd gear
synchronizer ring of Transmission on vehicle model.
Step 1
First, refer to the illustration. The 3rd gear synchronizer ring belongs to Group D and 1st gear syn-
chronizer ring belongs to Group E :, their replacement is covered in Group Work (D) and (E).
Step 2
In this case, the flat rate time of 'T/M ASSY .............OVERHAUL should be applied.
T/M ASSY................. OVERHAUL............... 6.0
The operation code is 222010 20

0 GENERAL
/8 GRAPHIC ILLUSTRATIONS
GRAPHIC ILLUSTRATIONS FRM000GRAPH11001
In order to make it easy to locate the operation code and flat rate, a simple graphic illustration page is
provided at the beginning of each group.
ILLUSTRATION FOR TRANSMISSION GROUP WORK
The alphabet letters within the illustration indicate the operation code's work code

GENERAL 00
GRAPHIC ILLUSTRATIONS /9
DOIIF000R9004

0 GENERAL
/ 10 APPLICABLE VEHICLE MODEL
ILLUSTRATION FOR GENERAL WORK

The 4 – digit numbers within the illustration are the operation code's 2 – digit numbers for the medium
group and 2 – digit numbers for the minor group
DOIIF000R9003
APPLICABLE VEHICLE MODEL FRM000MODEL11002
Abbreviaton Vehicle Destination Model code Engine Transmission

name Vehicle model Model series model model
YNSXRMA0
F5M42
Proton Malaysia / YNJXRMA0
FZ FZ6 S4PH
(EXORA) General Export YRJXRMA0
F4A4B
YRHXRMA0
ENGINE AND TRANSMISSION MODELS AND THEIR ABBREVIATION
Engine model Abbreviation of engine model
S4PH – 1597 cm³ (97.45 cu.in) S4P
Transmission series Series name (Model)
A/T F4A4B
FF 2WD
M/T F5M42

GENERAL 00
/ 11
FRM000TERMS11001
DEFINITION OF TERMS
1. Incl:
Operation which is“Included” in the main operation, such as removal/Installation of related parts, air
bleeding, adjustment, test run, etc.
2. Exc:
Addition of “Excluding”,indicates operation which is excluded from the main operation
3. Additional time allowance:
There are instances in which the flat rate times for main operation are affected by whether or not
various components (such as, air conditioner, power steering, etc.) are fitted. In such instances, the
flat rate times shown in the “Additional time allowance” column should be added to the flat rate times
for the main operation. If, however, the flat rate times shown in the “Additional time allowance”
column are accompanied by a minus (-) sign, such flat rate times should be subtracted from the flat
rate times for the operation.
4. Additional operation:
For operations for which there is a high degree of probability of being done at the same time as the
main operation, this is shown in the “ dditional operation” column thus establishing the flat rate times
if both operations are done at the same time. The total flat rate times (if an operation shown in this
column is done at the same time as a main operation) are determined by adding the flat rate times for
the additional operation to the flat-rate times for the main operation.
5. R&I:
“Removal and installation”
6. T/M:
“Transmission”
7. SOHC:
“Single Overhead Camshaft”
8. OHC:
“ ouble Overhead Camshaft”
9. ISC:
“Idle speed Control”
10. TCL:
“Traction Control”
11. ABS:
“Anti-skid Brake System”
12. FCC:
“Front Catalytic Converter”
13. CC:
“Catalytic Converter”
14. MPI:
“Multi Point Injection”
15. PADT:
“Proton Advance Diagnostic Tool”

0 GENERAL
/ 12
NOTE

ENGINE 11
Content /1
11 ENGINE
GRAPHICAL ILLUSTRATIONS ........................................................11/2
ENGINE .................................................................................. 11/6

11 ENGINE
/2 GRAPHICAL ILLUSTRATIONS
GRAPHICAL ILLUSTRATIONS FRM011GRAPH11004
DOIQF011R12001

ENGINE 11
GRAPHICAL ILLUSTRATIONS /3
DOIQF011R12002

11 ENGINE
DOIQF011R12003

ENGINE 11
DOIQF011R12004

11 ENGINE
/6 ENGINE
ENGINE FRM0110110011004
OPERATION
CR
CODE DESCRIPTION
1100 ENGINE
110010 10 ENGINE ASSY ... REPLACEMENT 5.3
Incl
Engine-adjustment
Test Run
Transmission assy R&I
110010 20 ENGINE ASSY ... OVERHAUL 18.1
Incl
Engine assy-R&I
Valve-lapping & correction
Cleaning
Engine-adjustment
Test Run
Exc.
Electrical equipment-overhaul
110010 40 ENGINE ASSY ... ADJUSTMENT 1.0
110010 92 IGNITION TIMING- DJUSTMENT 0.3
110011 10 SHORT ENGINE ASSY ... EPL CEMENT 10.6
Incl
Engine assy- &I
Engine-adjustment
Exc.
Electrical equipment-overhaul
Injection pump-overhaul
Additional operation.
A4 ... Cylinder head assy ... overhaul 4.2

1111 ENGINE CYLIN ER BLOCK GENERAL FRM0110111111003
111110 10 CYLINDER BLOCK ASSY ... REPLACEMENT 10.6

Incl
Engine assy-R&I
Engine-adjustment

1112 ENGINE CYLINDER HEAD GENERAL FRM0110111211003
111210 10 CYLINDER HEAD ASSY ... REPLACEMENT 4.9

Incl
Cylinder head gasket-replace
Valve timing related parts-R&I
Engine-adjustment
Rocker arm and shaft-R&I
Valve-lapping and correction
Exc.
Valve guide and seat-replace
111210 20 CYLINDER HEAD ASSY ... OVERHAUL 5.8

ENGINE 11
ENGINE /7
OPERATION
CR
CODE DESCRIPTION
Incl
Cylinder head assy-R&I

111221 10 CYLINDER HEAD GASKET ... REPLACEMENT 3.8
Incl
Engine-adjustment
1113 ENGINE CASE & COVER GENERAL FRM0110111311004
111310 10 ROCKER COVER ASSY ... REPLACEMENT 0.6

111311 10 ROCKER COVER GASKET ... REPLACEMENT 0.6
111320 10 OIL PAN ASSY ... REPLACEMENT 2.0
111321 10 OIL PAN GASKET (LIQUID GASKET) ... REPLACEMENT 2.0
Incl
Lift of engine
Oil pan assy-R&I
111330 10 FRONT CASE ASSY ... REPL CEMENT 5.2
Incl
Timing belt (A)-R&I

Oil pan assy-R&I
111331 10 FRONT CASE GASKET ... REPL CEMENT 5.2
Incl
Timing belt (A)- &I

Oil pan assy- &I
111351 10 TIMING BELT F ONT UPPER COVER ... REPLACEMENT 0.6
111352 10 TIMING BELT F ONT LOWER COVER ... REPLACEMENT 0.8
111365 10 ENGINE COVER ... REPLACEMENT —
111382 10 LA ER FRAME ... REPLACEMENT 0.7
Incl
Rocker cover assy-R&I
1121 ENGINE PISTON GENERAL FRM0110112111003
112110 10 PISTON ... REPLACEMENT (ALL) 8.9

Incl
Engine assy-R&I
Oil pan assy-R&I

112120 10 PISTON RING ... REPLACEMENT (ALL) 8.9
Incl
Engine assy-R&I
Oil pan assy-R&I

1122 ENGINE CONNECTING ROD GENERAL FRM0110112211003
112210 20 CONNECTING ROD ASSY ... REPLACEMENT (ALL) 8.8

11 ENGINE
/8 ENGINE
OPERATION
CR
CODE DESCRIPTION
Incl
Engine assy-R&I
Oil pan assy-R&I

112220 10 CONNECTING ROD BEARING (BIG END) ... REPLACEMENT (ALL) 2.5
Incl
Oil pan assy-R&I
1123 ENGINE CRANKSHAFT GENERAL FRM0110112311004
112310 10 CRANKSHAFT ASSY ... REPLACEMENT 10.4

Incl
Engine assy-R&I

112320 10 CRANKSHAFT MAIN-BE RING ... REPL CEMENT (ALL) 10.4
Incl
Crankshaft- &I
Engine assy- &I

112342 10 CRANKSHAFT OIL SEAL (F ONT) ... REPLACEMENT 1.7
Incl
Timing belt-R&I
Crankshaft pulley-R&I
112352 10 CRANKSHAFT OIL SEAL (REAR) ... REPLACEMENT 5.5
Incl
Oil pan assy-R&I
Flywheel-R&I
Rear cover-R&I
Clutch cover assy-R&I
Transmission assy-R&I
112370 10 CRANKSHAFT PULLEY ... REPLACEMENT 0.6
1124 ENGINE FLYWHEEL GENERAL FRM0110112411004
112410 10 FLYWHEEL ... REPLACEMENT 4.9

Incl
Additional time allowance
S1 ... Sub frame-R&I 1.1

112411 10 FLYWHEEL RING GEAR ... REPLACEMENT 4.9
Incl

112420 10 DRIVE PLATE ... REPLACEMENT 4.9

ENGINE 11
ENGINE /9
OPERATION
CR
CODE DESCRIPTION
Incl

1131 INLET VALVE GENERAL FRM0110113111003
113110 10 INLET VALVE ... REPLACEMENT (ALL) 4.3

Incl

Engine-adjustment
A3 ... Exhaust valve (all) ... replacement 0.5

113113 10 INLET VALVE STEM SEAL ... REPLACEMENT 4.3
Incl
Engine-adjustment
A3 ... Exhaust valve stem seal (all) ... replacement 0.5

113114 10 INLET VALVE SP ING ... EPLACEMENT (ALL) 4.1
Incl
Engine-adjustment
Cylinder head assy- &I
A7 ... Exhaust valve spring ... replacement 0.4

113150 10 EXHAUST VALVE ... REPLACEMENT (ALL) 4.3
Incl

Engine-adjustment
113153 10 EXHAUST VALVE STEM SEAL ... REPLACEMENT (ALL) 4.3
Incl
Engine-adjustment
113154 10 EXHAUST VALVE SPRING ... REPLACEMENT 4.1
Incl
Engine-adjustment
1132 ENGINE ROCKER ARM & SHAFT GENERAL FRM0110113211003
113235 10 TAPPET LASH ADJUSTER ... REPLACEMENT (ALL) 2.4

Incl
Camshaft-R&I
Engine-adjustment
1133 ENGINE CAMSHAFT GENERAL FRM0110113311003
113310 10 CAMSHAFT ASSY ... REPLACEMENT (One piece) 2.4

11 ENGINE
/ 10 ENGINE
OPERATION
CR
CODE DESCRIPTION
Incl
Engine-adjustment
Timing belt (A) - R&I
P2 ... Per 2 pieces 0.2

113340 10 CAMSHAFT OIL SEAL ... REPLACEMENT (One piece) 1.8
Incl
Timing belt (A) - R&I
Engine-adjustment

1134 ENGINE TIMING BELT GENER L FRM0110113411006
113410 10 TIMING BELT (A) ... REPL CEMENT 1.7

Incl
Timing belt cover-R&I
Engine-adjustment
A1 ... Timing belt tensioner … replacement 0.1

113430 10 FEAD BELT (AUXILA IES BELT) ... EPLACEMENT 0.5
1135 ENGINE BELT TENSIONER FRM0110113511004
113510 10 TIMING BELT TENSIONER ASSY ... REPLACEMENT 1.7

Incl
Engine-adjustment
113530 10 AUTO TENSIONER ... REPLACEMENT 0.5
1136 ENGINE SPROCKET GENERAL FRM0110113611004
113610 10 CRANKSHAFT SPROCKET ... REPLACEMENT 1.7

Incl
Timing belt - R&I
113620 10 CAMSHAFT SPROCKET ... REPLACEMENT (One piece) 1.7
Incl
Timing belt (A)-R&I

LUBRICATION 12
Content /1
12 LUBRICATION
LUBRICATION .......................................................................... 12/3

12 LUBRICATION
DOIQF012R12001

LUBRICATION 12
LUBRICATION /3
LUBRICATION FRM0120121011003
OPERATION
CR
CODE DESCRIPTION
1210 ENGINE OIL PUMP GENERAL

121010 10 OIL PUMP ASSY ... REPLACEMENT 5.6
Incl
Front case-R&I
Timing belt-R&I
121010 20 OIL PUMP ASSY ... OVERHAUL 5.8
Incl
Oil pump assy-R&I
121013 10 INNER GEAR ... REPLACEMENT 5.4
Incl
Oil pan assy-R&I

Timing belt-R&I
121014 10 OUTER GEAR ... REPL CEMENT 5.4
Incl
Oil pan assy-R&I

Timing belt-R&I
121061 10 OIL SCREEN (STR INER) ... REPL CEMENT 1.9
Incl
Oil pan assy- &I

1220 ENGINE OIL FILTER & B ACKET GENERAL FRM0120122011003
122020 10 OIL FILTER ASSY ... EPLACEMENT 0.4

1230 ENGINE OIL COOLER GENERAL FRM0120123011004
123010 10 OIL COOLER ASSY... REPLACEMENT 1.2

1250 ENGINE OIL FILLER GENERAL FRM0120125011003
125012 10 OIL FILLER CAP ... REPLACEMENT 0.2

1282 SWITCH GENERAL FRM0120128211003
128201 10 OIL PRESSURE SWITCH ... REPLACEMENT 0.4

128201 84 OIL PRESSURE SWITCH ... REPLACEMENT 0.2
1286 SOLENOID VALVE GENERAL FRM0120128611003
128601 10 CPS SOLENOID VALVE ... REPLACEMENT 0.3

12 LUBRICATION
/4 LUBRICATION
NOTE

FUEL 13
Content /1
13 FUEL
FUEL ..................................................................................... 13/6

13 FUEL
DOIQF013R12001

FUEL 13
DOIQF013R12002

13 FUEL
DOIQF013R12003

FUEL 13
DOIQF013R12004

13 FUEL
/6 FUEL
FUEL FRM0130133111003
OPERATION
CR
CODE DESCRIPTION
1331 ECI-MULTI GENERAL
133110 10 INJECTOR (ECI-MULTI) ... REPLACEMENT 0.5
A9 ... Inspection by PADT 0.2

133111 10 INSULATOR (ECI-MULTI) ... REPLACEMENT (AII) 0.5
133121 10 THROTTLE BODY (ECI-MULTI) ... REPLACEMENT 0.4
133131 10 INJECTION PRESSURE REGULATOR (ECI-MUL I) ... REPLACEMENT 0.4
133132 10 DELIVERY PIPE (ECI-MULTI) ... REPLACEMENT 0.5
1350 FUEL PUMP GENERAL FRM0130135011003
135020 10 FUEL PUMP ASSY (ELECTRICAL) ... REPLACEMENT 0.5

A9 ... Inspection by P DT 0.2

1360 FUEL TANK GENER L FRM0130136011003
136010 10 FUEL TANK ASSY ... REPL CEMENT 1.1

136021 10 FUEL TANK FILLER NECK HOSE ... REPL CEMENT 0.5
136022 10 FUEL TANK B EATHER HOSE ... EPLACEMENT 0.5
136032 10 FUEL TANK VAPOR HOSE ... EPLACEMENT 0.4
1370 FUEL LINE GENE AL FRM0130137011003
137010 10 FUEL FILTER ASSY ... EPLACEMENT 0.3

137031 10 FUEL HOSE (ENGINE) ... REPLACEMENT 0.6
137051 10 FUEL HOSE (FUEL TANK) ... REPLACEMENT 0.5
137053 10 FUEL HOSE RETURN (FUEL TANK) ... REPLACEMENT 0.5
137073 10 FUEL RETURN PIPE ... REPLACEMENT 0.6
137075 10 FUEL VAPOR PIPE ... REPLACEMENT 0.6
137086 10 FUEL CUT-OFF VALVE ... REPLACEMENT 0.5
1383 SENSOR AND GAUGE UNIT GENERAL FRM0130138311006
138311 10 WATER TEMPERATURE SENSOR (ECI-MULTI) ... REPLACEMENT 0.3


138313 10 THROTTLE POSITION SENSOR (ECI-MULTI) ... REPLACEMENT 0.5

138320 10 ACCELERATING POSITION SENSOR ... REPLACEMENT 0.4

138323 10 TEMPERATURE PRESSURE SENSOR / MAP SENSOR ... REPLACEMENT 0.3

138351 10 OXYGEN SENSOR (BEFORE FCC) ... REPLACEMENT 0.3

FUEL 13
FUEL /7
OPERATION
CR
CODE DESCRIPTION
1384 RELAY AND FLASHER UNIT GENERAL FRM0130138411003
138401 10 MPI CONTROL RELAY ... REPLACEMENT 0.2

1385 CONTROL UNIT GENERAL FRM0130138511004
138501 10 MPI CONTROL UNIT ... REPLACEMENT 0.4


13 FUEL
/8 FUEL
NOTE

COOLING 14
Content /1
14 COOLING
COOLING ................................................................................ 14/5

14 COOLING
DOIQF014R12001

COOLING 14
DOIQF014R12002

14 COOLING
DOIQF014R12003

COOLING 14
COOLING /5
COOLING FRM0140141011004
OPERATION
CR
CODE DESCRIPTION
1410 WATER PUMP GENERAL
141010 10 WATER PUMP ASSY ... REPLACEMENT 2.1
Incl

Engine-adjustment
141012 10 WATER PUMP SEAL ... REPLACEMENT 2.1
Incl
Water pump assy-R&I

141025 10 WATER PUMP RECIRCULATION ASSY ... REPLACEMENT 0.6
1421 THERMOSTAT GENERAL FRM0140142111003
142110 10 THERMOSTAT ... REPLACEMENT 0.5

1422 ENGINE WATER PIPE & HOSE GENERAL FRM0140142211004
142221 10 BY PASS HOSE / W TER RETURN HOSE ... REPLACEMENT 0.5

142225 10 WATER THERMOST T PIPE ... REPL CEMENT 1.1
142233 10 WATER THERMOST T HOSE ... REPL CEMENT 1.2
142234 10 WATER ETU N ... EPL CEMENT 1.2
142235 10 WATER FEED HOSE ... EPLACEMENT 1.2
1440 COOLING FAN & COUPLING GENERAL FRM0140144011004
144030 10 COOLING FAN ASSY (ELECT IC) ... REPLACEMENT 0.5

144031 10 COOLING FAN (ELECT IC) ... EPLACEMENT 0.8
1450 RA IATOR & RESERVOIR (SURGE) TANK GENERAL
FRM0140145011004
145010 10 RA IATOR ASSY ... REPLACEMENT 0.8

Incl
Grille-R&I
Condenser and receiver-R&I
145034 10 RADIATOR SHROUD ... REPLACEMENT 0.8
Incl
Radiator assy-R&I
145050 10 RESERVOIR (CONDENSE) TANK ASSY ... REPLACEMENT 0.3
1460 RADIATOR WATER LINE GENERAL FRM0140146011003
146021 10 RADIATOR HOSE (UPPER) ... REPLACEMENT (One piece) 0.4

146022 10 RADIATOR HOSE (LOWER) ... REPLACEMENT (One piece) 0.7
146023 10 RUBBER HOSE (RADIATOR TO TANK) ... REPLACEMENT (One piece) 0.2
1481 MOTOR AND ACTUATOR GENERAL FRM0140148111003
148101 10 RADIATOR FAN MOTOR ... REPLACEMENT 0.8

148201 10 RADIATOR FAN MOTOR THERMO SWITCH (SENSOR) ... REPLACEMENT —

148301 10 WATER TEMPERATURE GAUGE UNIT ... REPLACEMENT 0.3

14 COOLING
/6 COOLING
OPERATION
CR
CODE DESCRIPTION
148401 10 RADIATOR FAN MOTOR RELAY ... REPLACEMENT 0.2

INTAKE AND EXHAUST 15
Content /1
15 INTAKE AND EXHAUST

INTAKE & EXHAUST .................................................................. 15/5

DOIQF015R12001

DOIQF015R12002

DOIQF015R12003

INTAKE & EXHAUST /5
INTAKE & EXHAUST FRM0150151111004
OPERATION
CR
CODE DESCRIPTION
1511 INTAKE MANIFOLD GENERAL
151110 10 INTAKE MANIFOLD ASSY ... REPLACEMENT 1.4
Incl
Air cleaner assy-R&I

Engine-adjustment
151111 10 INTAKE MANIFOLD O-RING ... REPLACEMENT (ALL) 1.2
Incl
Air cleaner assy-R&I

151143 10 VARIABLE AIR VACCUM TANK ... REPLACEMENT —
1512 AIR CLEANER GENERAL FRM0150151211003
151210 10 AIR CLEANER ASSY ... REPLACEMENT 0.4

151211 10 AIR CLEANER ELEMENT ... REPLACEMENT 0.2
151250 10 RESONATOR REPL... CEMENT —
1531 EXHAUST MANIFOLD GENER L FRM0150153111004
153110 10 EXHAUST MANIFOLD SSY ... REPL CEMENT 1.1

153120 10 EXHAUST MANIFOLD G SKET ... EPL CEMENT 1.1
153122 10 EXHAUST MANIFOLD COVER ... EPLACEMENT 0.4
1532 FRONT EXHAUST PIPE GENERAL FRM0150153211003
153210 10 FRONT EXHAUST PIPE ASSY ... EPLACEMENT 0.5

153211 10 FRONT EXHAUST PIPE GASKET ... REPLACEMENT 0.4
1535 MAIN MUFFLER GENERAL FRM0150153511003
153510 10 MAIN MUFFLER ASSY ... REPLACEMENT 0.5

1537 CATALYTIC CONVERTER GENERAL FRM0150153711003
153710 10 CATALYTIC CONVERTER ASSY (FRONT) ... REPLACEMENT 0.8

158112 10 VIM MOTOR (INTAKE MANIFOLD) ... REPLACEMENT 1.2

Incl
Intake Manifold-R&I
158113 10 VIM ACTUATOR (INTAKE MANIFOLD) ... REPLACEMENT —
158303 10 MOTOR SENSOR REPLACEMENT... 1.2

/ 6. INTAKE & EXHAUST
NOTE

Content /1
ENGINE ELECTRICAL .................................................................. 16/4

DOIQF016R12001

DOIQF016R12002

/4 ENGINE ELECTRICAL
ENGINE ELECTRICAL FRM0160161111002
OPERATION
CR
CODE DESCRIPTION
1611 ALTERNATOR GENERAL
161110 10 ALTERNATOR ASSY ... REPLACEMENT 1.2
161110 20 ALTERNATOR ASSY ... OVERHAUL 2.2
Incl
Alternator assy-R&I
Defective parts-replacement
161121 10 ALTERNATOR IC REGULATOR ... REPLACEMENT 1.8
Incl
Alternator assy-R&I
161122 10 ALTERNATOR BRUSH HOLDER ASSY ... REPLACEMENT 1.6
Incl
Alternator assy-R&I
161125 10 ALTERNATOR RECTIFIER ... REPL CEMENT 1.6
Incl
Alternator assy-R&I
161126 10 ALTERNATOR ST TOR SSY... REPL CEMENT 1.6
Incl
Alternator assy- &I
161127 10 ALTE NATOR OTOR ASSY ... EPLACEMENT 1.6
Incl
Alternator assy- &I
1621 STARTER GENERAL FRM0160162111002
162110 10 STARTER ASSY ... REPLACEMENT 1.5

162110 20 STARTER ASSY ... OVERHAUL 2.5
Incl
Starter assy-R&I
162112 10 STARTER SWITCH ASSY ... REPLACEMENT 1.8
Incl
Starter assy-R&I
162113 10 STARTER ARMATURE ASSY ... REPLACEMENT 2.0
Incl
Starter assy-R&I
162122 10 STARTER BRUSH ... REPLACEMENT 2.0
Incl
Starter assy-R&I
162124 10 STARTER OVERRUNNING CLUTCH ... REPLACEMENT 2.0
Incl
Starter assy-R&I
162126 10 STARTER GEAR ASSY ... REPLACEMENT 2.0
Incl
Starter assy-R&I

ENGINE ELECTRICAL /5
OPERATION
CR
CODE DESCRIPTION
162128 10 STARTER LEVER SET ASSY ... REPLACEMENT 2.0
Incl
Starter assy-R&I
1631 IGNITION COIL GENERAL FRM0160163111002
163110 10 IGNITION COIL ASSY ... REPLACEMENT (All) 0.8


1634 CABLE GENERAL FRM0160163411003
163410 10 HIGH TENSION CABLE ASSY ... REPLACEMENT (All) 0.2

1634 CABLE GENERAL FRM0160163411004
163410 10 HIGH TENSION CABLE ASSY ... REPLACEMENT (ALL) 0.2

1635 SPARK PLUG GENERAL FRM0160163511002
163510 10 SPARK PLUG ASSY ... REPL CEMENT ( LL) 0.4

1683 SENSOR AND G UGE UNIT GENER L FRM0160168311002
168301 10 KNOCK SENSOR ... REPL CEMENT 0.2


168321 10 C ANKSHAFT ANGLE SENSOR ... REPLACEMENT 0.3

168322 10 CAMSHAFT ANGLE SENSOR ... REPLACEMENT 0.4

168401 10 STARTER RELAY ... REPLACEMENT 0.2

168441 10 ALTERNATOR RELAY ... REPLACEMENT —

/6 ENGINE ELECTRICAL
NOTE

EMISSION CONTROL 17
Content /1
17 EMISSION CONTROL

17 EMISSION CONTROL
DOIQF017R12001

EMISSION CONTROL 17
DOINF017R09002

17 EMISSION CONTROL
/4 EMISSION CONTROL
EMISSION CONTROL FRM0170171111002
OPERATION
CR
CODE DESCRIPTION
1711 ACCELERATOR GENERAL
171111 10 ACCELERATOR PEDAL ... REPLACEMENT 0.4
1731 VAPOR PREVENTIVE DEVICE GENERAL FRM0170173111002
173110 10 CANISTER ASSY ... REPLACEMENT 0.6

1736 BLOW-BY GAS REDUCING DEVICE GENERAL FRM0170173611003
173630 10 BREATHER HOSE ... REPLACEMENT (One piece) 0.2

178201 10 ACCELERATOR PEDAL SWITCH (AUTO CRUISE) ... REPLACEMENT –

178203 10 AUTO CRUISE SWITCH ... REPLACEMENT –
178204 10 AUTO CRUISE M IN SWITCH ... REPL CEMENT –
1783 SENSOR AND G UGE UNIT GENER L FRM0170178311002
178315 10 ACCELERATOR PED L SENSOR ... REPL CEMENT 0.4

1785 CONT OL UNIT GENE L FRM0170178511002
178501 10 AUTO C UISE ( AUTO SPEED) CONTROL UNIT ... REPLACEMENT 0.5
1786 SOLENOID VALVE GENE AL FRM0170178611002
178635 10 PURGE CONT OL VALVE ... EPLACEMENT 0.3

178661 10 CANISTER BLEED SOLENOID VALVE ... REPLACEMENT 0.4

CLUTCH 21
Content /1
21 CLUTCH
CLUTCH ................................................................................. 21/3

21 CLUTCH
DOIQF021R12001

CLUTCH 21
CLUTCH /3
CLUTCH FRM0210211111002
OPERATION
CR
CODE DESCRIPTION
2111 CLUTCH DISC & COVER ASSY GENERAL
211110 10 CLUTCH DISC ... REPLACEMENT 4.5
Incl
Clutch cover assy-R&I
211120 10 CLUTCH COVER ASSY ... REPLACEMENT 4.5
Incl
2120 CLUTCH CONTROL GENERAL FRM0210212011002
212011 10 CLUTCH PEDAL ... REPLACEMENT 0.6

212011 40 CLUTCH PEDAL ... ADJUSTMENT 0.2
212014 10 CLUTCH PEDAL BUSHING ... REPLACEMENT 0.6
Incl
Clutch pedal assy-R&I
Pedal stroke-adjustment
212030 10 CLUTCH MASTER CYLINDER SSY ... REPL CEMENT 0.6
Incl
Air Bleeding
212030 20 CLUTCH MASTER CYLINDER ASSY ... OVERHAUL —
Incl
Air Bleeding
212050 10 CLUTCH RELEASE CYLINDER ASSY ... REPLACEMENT 0.3
Incl
Air Bleeding
212050 20 CLUTCH RELEASE CYLINDER ASSY ... OVERHAUL 0.4
Incl
Air Bleeding
212071 10 CLUTCH RELEASE BEARING ... REPLACEMENT 3.0
Incl
212074 10 CLUTCH RELEASE FORK ... REPLACEMENT 3.1
Incl
212081 10 CLUTCH HOSE ... REPLACEMENT (One piece) 0.4
Incl
Air Bleeding

21 CLUTCH
/4 CLUTCH
NOTE

Content /1
5MTT200A .............................................................................. 22/4
MANUAL TRANSMISSION ........................................................... 22/6

DOIQF022R12001

DOIQF022R12002

/4 5MTT200A
5MTT200A FRM022GROUP11002
GROUP WORK A :CLUTCH HOUSING AND RELATED PARTS

– Clutch housing plug – Taper bearing outer
ring
– Differential oil seal – Clutch housing dow-
el
– Input shaft oil seal – Reverse idler shaft
– Clutch housing – Output shaft front
bearing outer ring
–Reverse relay arm –Speedometer assy
–Breather pipe –Bolt
–Shift shaft bush –Magnet
–Shift shaft relay bush –Reverse light switch assy
– Output shaft funnel – Drail oil plug
GROUP WORK B : DIFFERENTI L ND RELATED PARTS
– Differential taper rolling bearing – Planet pinion shaft
– Speedometer drive gear – Planet pinion
– Bolt – Differential side gear
– Final drive driven gear – Differential case
– etainer ring
G OUP WO K C : INPUT SHAFT AND RELATED PARTS
– Input shaft front bearing – Input shaft
– Input shaft rear bearing
GROUP WORK D :FORK ASSYAND RELATED PARTS
st nd
– 1 /2 gear fork assy – Shift shaft assy
rd th
– 3 / 4 gear fork assy – Interlock plate
th
– 5 / Rev gear fork shaft assy
GROUP WORK E : REVERSE GEAR AND RELATED PARTS
– Reverse idler gear – E type retainer ring
– Reverse gear back spring – Check gate assy
– Reverse shift lever – Bolt
GROUP WORK F : DIFFERENTIAL ASSEMBLY AND RELATED PARTS
st nd
– Retainer ring – 1 / 2 gear syn-
chronizer inner ring
– Output shaft rear bearing – synchronizer cone
ring
th st nd
– 4 speed ring gear – 1 / 2 gear syn-
chronizer outer ring
– rd th th –Retainer ring
3 / 4 5 synchronizer ring
–Retainer ring –1st / 2nd gear syn-chronizer
spring

5MTT200A /5
GROUP WORK F : DIFFERENTIAL ASSEMBLY AND RELATED PARTS

rd th st nd
– 3 / 4 gear synchronizer spring – 1 / 2 gear syn-
chronizer slider
rd th st nd
– 3 / 4 gear synchronizer slider – 1 / 2 gear syn-
chronizer hub
rd th st nd
– 3 / 4 gear synchronizer hub – 1 / 2 gear syn-
chronizer sleeve
rd th st
– 3 / 4 gear synchronizer sleeve – 1 speed ring gear
rd
– 3 speed driven gear – Retainer ring
– Thrust ring – Output shaft front
bearing inner ring
– Thrust washer – Output ring
rd
– 2 speed driven gear
GROUP WORK G : TRANSMISSION CASE AND RELATED PARTS
– Taper bearing outer ring – Shift control arm
– Taper washer – Shift shaft oil seal
– Fork bush – Select lever
– Transmission case – Shift shaft boot
– Differential oil seal – Shift shaft screw
– Stud – Shift lever
– Input shaft fastening ring – Interlock retainer
seat assy
– Output shaft fastening ring – E type retainer ring
– Shift shaft bush
GROUP WORK H : REAR COVER AND RELATED PARTS
th
– Stud – 5 speed driven gear
– Bolt – Spring pin
th
– Rear cover – 5 gear fork assy
– Retainer ring – Snap ring
th th
– 5 gear spacer – 5 speed drive gear
th
– 5 gear synchronizer assy

/6 MANUAL TRANSMISSION
MANUAL TRANSMISSION FRM0220221111002
OPERATION
CR
CODE DESCRIPTION
2211 TRANSMISSION CONTROL GENERAL
221111 10 T/M SHIFT LEVER ... REPLACEMENT 0.8
Incl
Floor console assy-R&I
221112 10 T/M SHIFT LEVER KNOB ... REPLACEMENT 0.2
221115 10 T/M SHIFT LEVER BOOT (COVER) ... REPLACEMENT 0.2
221171 10 T/M CONTROL CABLE ... REPLACEMENT 1.2
Incl
Floor console assy-R&I
2220 TRANSMISSION UNIT GENERAL FRM0220222011002
222010 10 T/M ASSY ... REPLACEMENT 4.4

Incl
Drive shaft assy-R&I
222010 20 T/M ASSY ... OVERH UL 7.4
Incl
Transmission assy- &I
222010 9A T/M G OUP WO K (A) 4.6
Incl
222010 9B T/M GROUP WORK (B) 4.8
Incl
efective parts-replacement
222010 9C T/M GROUP WORK (C) 4.8
Incl
222010 9D T/M GROUP WORK (D) 5.4
Incl
222010 9E T/M GROUP WORK (E) 5.6
Incl
222010 9F T/M GROUP WORK (F) 5.5
Incl
222010 9G T/M GROUP WORK (G) 5.9

MANUAL TRANSMISSION /7
OPERATION
CR
CODE DESCRIPTION
Incl
222010 9H T/M GROUP WORK (H) 5.9
Incl
222010 9J T/M GROUP WORK (J) 5.8
Incl
2221 TRANSMISSION CASE & HOUSING GENERAL FRM0220222111002
222113 80 T/M DRIVE SHAFT OIL SEAL-REPLACEMENT (LE T) 0.9

Incl

222113 82 T/M DRIVE SHAFT OIL SE L-REPL CEMENT (RIGHT) 0.9
Incl

2222 T ANSMISSION GE SHIFTER GENERAL FRM0220222211001
222260 90 POPPET BALL, SP ING, PLUG ... REPLACEMENT 0.4

2240 T ANSMISSION ATTACHING EQUIPMENT GENERAL
FRM0220224011002
224011 10 SPEE OMETER RIVEN GEAR SLEEVE ... REPLACEMENT 0.4

224013 10 SPEE OMETER RIVEN GEAR ... REPLACEMENT 0.4
224021 10 SPEE OMETER CABLE ... REPLACEMENT —
228201 10 BACK-UP SWITCH ... REPLACEMENT 0.4

/8 MANUAL TRANSMISSION
NOTE

TRANSMISSION (CVT) 23
Content /1
23 TRANSMISSION (CVT)
GRAPHICAL ILLUSTRATIONS ........................................................ 23/2
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) ............................. 23/4

DOIQF023R12001

DOIQF023R12002

/ 4. CONTINUOUSLY VARIABLE TRANSMISSION (CVT)
CONTINUOUSLY VARIABLE TRANSMISSION (CVT) FRM023GROUP11003
GROUP WORK A : RELATED PARTS

– Flange bolt – Clamp primary cover
– O-ring primary cover – Flange bolt
– Primary cover
GROUP WORK B : RELATED PARTS
– Primary ball bearing – O-ring oil pump
– Primary nut – Oil pump complete
– Disc spring – O-ring oil pump
– Sealing ring oil pump
GROUP WORK C : RELATED PAR S
– Sealing ring plug – Sealing ring
– Plug – O-ring secondary
cover
– O-ring secondary cover – Secondary cover
GROUP WORK D : RELATED P RTS
– Bolt – Speed sensor
– Fixing plate sec.speed sensor – Flange bolt
– Speed sensor sec.complete
G OUP WO K E : RELATED PARTS
– Protection cap connector – Wiring loom vt2
– Holding clip

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) /5
OPERATION
CR
CODE DESCRIPTION
2311 TRANSMISSION CONTROL GENERAL
231110 10 T/M SELECTOR LEVER ASSY ... REPLACEMENT 0.8
231112 10 T/M SELECTOR HANDLE ... REPLACEMENT 0.6
T2 ... CFE Engine – 0.4

231118 10 T/M INDICATOR PANEL ... REPLACEMENT 0.4
231131 10 T/M CONTROL (SELECT) CABLE ... REPLACEMENT 1.3
2330 TRANSMISSION UNIT GENERAL FRM0230233011003
233010 10 T/M ASSY ... REPLACEMENT 4.8

Incl
Torque converter assy-R&I
Linkage-adjustment
233010 20 T/M ASSY ... OVERHAUL 11.2
Incl
233010 9A T/M GROUP WORK ( ) 6.9
Incl
P1 ... Continuously Varible Transmission <CVT> – 5.0

Exc
233010 9B T/M GROUP WORK (B) 7.1
Incl

Exc
233010 9C T/M GROUP WORK (C) 5.8
Incl

Exc
233010 9D T/M GROUP WORK (D) 7.1
Incl

OPERATION
CR
CODE DESCRIPTION
P1 ... Continuously Varible Transmission<CVT> – 6.3

Exc
233010 9E T/M GROUP WORK (E) 6.9
Incl

Exc
2331 TRANSMISSION CASE & HOUSING GENERAL FRM0230233111003
233113 80 T/M DRIVE SHAFT OIL SE L ... REPL CEMENT (LEFT) 1.4
Incl

233113 82 T/M D IVE SHAFT OIL SEAL ... EPLACEMENT (RIGHT) 1.2
Incl
Drive shaft assy- &I
Incl
rive shaft assy-R&I
233141 10 T/M OIL PAN ... REPLACEMENT 0.5
Incl
rive shaft assy-R&I
P1 ... Continuously Varible Transmission<CVT> 0.5
233142 10 T/M OIL PAN GASKET ... REPLACEMENT 1.0
Incl
Oil pan assy-R&I
2351 TRANSFER CASE & CHAIN COVER (REAR CASE) GENERAL
FRM0230235111003
235112 10 T/F CASE INPUT SHAFT OIL SEAL ... REPLACEMENT 3.6
Incl
2375 TRANSMISSION OIL LUBRICATION GENERAL FRM0230237511003
237510 10 T/M OIL HOSE ... REPLACEMENT 0.6

Incl
Front bumper-R&I
P1 ... Continuously Varible Transmission<CVT> 0.1

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) /7
OPERATION
CR
CODE DESCRIPTION
237530 10 T/M OIL COOLER ... REPLACEMENT 0.7
Incl
Front bumper-R&I
238311 10 INPUT SPEED SENSOR ... REPLACEMENT 1.6

Incl
Primary cover -R&I
238312 10 OUTPUT SPEED SENSOR ... REPLACEMENT 1.6
Incl
Oil pan assy-R&I

238501 10 T/M ELC CONTROL UNIT ... REPLACEMENT 0.5


A9 ... Inspection by P DT- II/Diagnostic tool 0.2

2389 ELECT ICAL EQUIPMENT GENER L (OTHERS) FRM0230238911003
238901 10 GEAR SHIFT LEVER INDICATOR LED BULB ... REPLACEMENT 0.2

NOTE

FRONT AXLE 26
Content /1
26 FRONT AXLE
FRONT AXLE ........................................................................... 26/3

26 FRONT AXLE
DOIQF026R12001

FRONT AXLE 26
FRONT AXLE /3
FRONT AXLE FRM0260266111001
OPERATION
CR
CODE DESCRIPTION
2661 FRONT AXLE HOUSING ASSY (EXCEPT DIFFERENTIAL)
266121 10 FRONT DRIVE KNUCKLE ... REPLACEMENT (One side) 1.3
266124 94 KNUCKLE OIL SEAL (INNER) ... REPLACEMENT (One side) 1.1
266124 96 KNUCKLE OIL SEAL (OUTER) ... REPLACEMENT (One side) 1.1
266141 10 FRONT WHEEL HUB ... REPLACEMENT (One side) 1.3
266142 10 FRONT WHEEL HUB BOLT ... REPLACEMENT (One side) 1.0
Incl
Hub assy-R&I
266148 10 WHEEL HUB BEARING (DOUBLE ROW ANGULAR CONTACT TYPE) ... REPLACE- 1.2
MENT (One side)
266180 80 FRONT DRIVE SHAFT ASSY (LH) ... REPLACEMENT 0.8
Incl
Wheel assy-R&I
266180 81 FRONT DRIVE SHAFT SSY (LH) ... OVERH UL 1.1
Incl
266180 82 FRONT D IVE SHAFT ASSY ( H) ... REPLACEMENT 0.9
Incl
Wheel assy- &I
266180 83 FRONT D IVE SHAFT ASSY ( H) ... OVERHAUL 1.2
Incl
rive shaft assy-R&I
266183 80 RIVE SHAFT BOOT (LH) ... REPLACEMENT —
Incl
266183 82 DRIVE SHAFT BOOT (T.J SIDE) ... REPLACEMENT 1.1
Incl

26 FRONT AXLE
/4 FRONT AXLE
NOTE

REAR AXLE 27
Content /1
27 REAR AXLE
REAR AXLE ............................................................................. 27/3

27 REAR AXLE
DOIQF027R12001

REAR AXLE 27
REAR AXLE /3
REAR AXLE FRM0270271111001
OPERATION
CR
CODE DESCRIPTION
2711 REAR AXLE SHAFT GENERAL
271141 10 REAR WHEEL HUB ... REPLACEMENT (One side) 0.6
Incl
Hub assy-R&I
Oil seal-replacement
Bearing-R&I
Hub bolt-R&I
271142 10 REAR WHEEL HUB BOLT ... REPLACEMENT (One side) 0.6
Incl
Hub assy-R&I
271144 10 REAR WHEEL HUB BEARING (INNER) ... REPLACEMENT (One side) 0.5
Incl
Hub assy-R&I

27 REAR AXLE
/4 REAR AXLE
NOTE

WHEEL AND TYRE 31
Content /1
31 WHEEL AND TYRE

WHEEL & TYRE ........................................................................ 31/3

31 WHEEL AND TYRE
DOIQF031R12001

WHEEL AND TYRE 31
WHEEL & TYRE /3
WHEEL & TYRE FRM0310311011001
OPERATION
CR
CODE DESCRIPTION
3110 WHEEL & TYRE GENERAL
311010 10 WHEEL ASSY ... REPLACEMENT (One piece) 0.2
311015 10 DISC WHEEL ... REPLACEMENT (One piece) 0.7
3120 WHEEL CAP GENERAL FRM0310312011001
312012 10 CENTER CAP ... REPLACEMENT (One piece) 0.2

3140 SPARE TYRE GENERAL FRM0310314011001
314021 10 SPARE TYRE CARRIER (HANGER) ... REPLACEMENT 0.2

31 WHEEL AND TYRE
/ 4. WHEEL & TYRE
NOTE

Content /1

POWER PLANT MOUNT .............................................................. 32/3

DOIQF032R12001

POWER PLANT MOUNT /3
POWER PLANT MOUNT FRM0320321111002
OPERATION
CR
CODE DESCRIPTION
3211 ENGINE & TRANSMISSION MOUNTING MEMBER GENERAL
321113 10 SUB FRAME MODULE ASSY ... REPLACEMENT 2.5
Incl
Lower arm assy-R&I

Wheel alignment check
3212 ENGINE SUPPORT GENERAL FRM0320321211004
321221 10 ENGINE FRONT ROLL STOPPER ... REPLACEMENT 0.8

321222 10 ENGINE MOUNTING ... REPLACEMENT 0.7
321223 10 T/M MOUNTING ... REPLACEMENT 0.5
321224 10 REAR ROLL STOPPER (INSULATOR) ... REPLACEMENT 0.8

/4 POWER PLANT MOUNT
NOTE

FRONT SUSPENSION 33
Content /1
33 FRONT SUSPENSION
FRONT SUSPENSION .................................................................. 33/3

33 FRONT SUSPENSION
DOIQF033R12001

FRONT SUSPENSION 33
FRONT SUSPENSION /3
FRONT SUSPENSION FRM0330330011001
OPERATION
CR
CODE DESCRIPTION
3300 FRONT SUSPENSION
330000 90 WHEEL END ALIGNMENT ... INSPECTION BY GAUGE 0.8
3331 SUSPENSION ARM GENERAL (MACPHERSON) FRM0330333111001
333110 10 LOWER ARM ALIGNMENT ... REPLACEMENT (One side) 0.8

333114 10 LOWER ARM BALL JOINT ... REPLACEMENT (One side) 0.7
3332 FRONT SPRING GENERAL (MACPHERSON) FRM0330333211001
333211 10 FRONT COIL SPRING ... REPLACEMENT (One side) 0.8

Incl
Strut assy-R&I
333213 10 FRONT STRUT INSULATOR ... REPLACEMENT (One side) 0.8
Incl
Strut assy-R&I
333213 40 FRONT STRUT INSULATOR ... DJUSTMENT (One side) 0.6
3333 FRONT STRUT GENER L (M CPHERSON) FRM0330333311001
333310 10 FRONT STRUT SSY ... REPL CEMENT (One side) 0.5
Incl
Wheel assy- &I

333311 10 FRONT ST UT SHOCK ABSO BER ... REPLACEMENT (One side) 0.8
Incl
Strut assy- &I

3334 FRONT STABILIZER GENERAL (MACPHERSON) FRM0330333411001
333411 10 FRONT STABILIZER BAR ... REPLACEMENT 2.8

333414 10 FRONT STABILIZER LINK KIT ... REPLACEMENT (One side) 0.5

33 FRONT SUSPENSION
/4 FRONT SUSPENSION
NOTE

REAR SUSPENSION 34
Content /1
34 REAR SUSPENSION
REAR SUSPENSION ................................................................... 34/3

34 REAR SUSPENSION
DOIQF034R12001

REAR SUSPENSION 34
REAR SUSPENSION /3
REAR SUSPENSION FRM0340346011001
OPERATION
CR
CODE DESCRIPTION
3460 REAR SUSPENSION GENERAL (TRAILING ARM)
346040 10 REAR CROSS MEMBER ASSY ... REPLACEMENT 2.1
3462 REAR SPRING GENERAL (TRAILING ARM) FRM0340346211001
346211 10 REAR COIL SPRING ... REPLACEMENT (One side) 0.6

346213 10 REAR STRUT INSULATOR ASSY ... REPLACEMENT (One side) 0.6
Incl
Strut assy-R&I
3463 REAR SHOCK ABSORBER GENERAL ( RAILING ARM)
FRM0340346311001
346310 10 REAR SHOCK ABSORBER ASSY ... REPLACEMENT (One side) 0.5
Incl.
Strut assy-R&I
346311 10 REAR SHOCK ABSORBER ... REPL CEMENT (One side) 0.6

34 REAR SUSPENSION
/4 REAR SUSPENSION
NOTE

SERVICE BRAKE 35
Content /1
35 SERVICE BRAKE
SERVICE BRAKES ...................................................................... 35/5

35 SERVICE BRAKE
DOIQF035R12001

SERVICE BRAKE 35
DOIQF035R12002

35 SERVICE BRAKE
DOIQF035R12003

SERVICE BRAKE 35
SERVICE BRAKES /5
SERVICE BRAKES FRM0350350011002
OPERATION
CR
CODE DESCRIPTION
3500 SERVICE BRAKE

350000 94 BRAKE SYSTEM ... BLEED 0.4
3511 BRAKE MASTER CYLINDER GENERAL FRM0350351111002
351110 10 BRAKE MASTER CYLINDER ASSY ... REPLACEMENT 0.9

Incl
Air bleeding
351110 20 BRAKE MASTER CYLINDER ASSY ... OVERHAUL 1.1
Incl
Master cylinder assy-R&I

3512 BRAKE BOOSTER GENERAL FRM0350351211002
351210 10 BRAKE BOOSTER SSY ... REPL CEMENT 1.3

Incl
Master cylinder assy-R&I

Air bleeding
351212 10 B AKE BOOSTER CHECK V LVE ... REPL CEMENT 0.3
3522 F ONT DISC B AKE GENERAL FRM0350352211002
352211 10 FRONT B AKE DISC ( OTO ) ... REPLACEMENT (One side) 0.5
Incl
Brake caliper assy- &I

Hub assy-R&I
A1 ... isc brake pad assy … replacement 0.1

352211 89 FRONT BRAKE ISC (BOTH SIDE) ... ON VEHICLE GRINDING 1.4
A1 ... Disc brake pad assy … replacement 0.1

352220 10 DISC BRAKE CALIPER ASSY ... REPLACEMENT (One side) 0.8
Incl
Wheel assy-R&I
Air bleeding
352220 20 DISC BRAKE CALIPER ASSY ... OVERHAUL (One side) 1.1
Incl
Brake caliper assy-R&I

352226 10 DISC BRAKE PAD ASSY ... REPLACEMENT (One side) 0.5
Incl
Wheel assy-R&I
3525 REAR DRUM BRAKE GENERAL FRM0350352511002
352520 10 DRUM BRAKE SHOE & LINING ASSY ... REPLACEMENT (One side) 0.6
Incl
Brake drum-R&I
Shoe clearance-adjustment
35 SERVICE BRAKE
/6 SERVICE BRAKES
OPERATION
CR
CODE DESCRIPTION
352530 10 DRUM BRAKE WHEEL CYLINDER ASSY ... REPLACEMENT (One side) 0.9
Incl
Brake drum-R&I
Brake shoe-R&I
Air bleeding
352530 20 DRUM BRAKE WHEEL CYLINDER ASSY ... OVERHAUL (One side) 1.0
Incl
Brake drum-R&I
352551 10 DRUM BRAKE BACKING PLATE ... REPLACEMENT (One side) 1.0
Incl
Axle shaft-R&I
Hub assy-R&I
Wheel cyIinder assy-R&I
Air bleeding
Brake cable-adjustment
352570 10 DRUM BRAKE SHOE DJUSTER SSY ( UTO) ... REPLACEMENT (One side) 0.5
Incl
Brake drum- &I
Brake shoe- &I
352591 10 BRAKE D UM ... EPLACEMENT (One side) 0.4
Incl
3531 BRAKE OIL LINE GENERAL FRM0350353111002
353121 10 BRAKE HOSE (FRONT) ... REPLACEMENT (One side) 0.6

Incl
Air bleeding
353123 10 BRAKE HOSE (REAR) ... REPLACEMENT (One side) 0.5
Incl
Air bleeding
353140 10 OIL RESERVOIR TANK ASSY ... REPLACEMENT 0.3
3532 BRAKE VACUUM LINE GENERAL FRM0350353211002
353221 10 VACUUM HOSE ... REPLACEMENT 0.3

3540 BRAKE CONTROL GENERAL FRM0350354011002
354011 10 BRAKE PEDAL ... REPLACEMENT 0.6

Incl
354011 40 BRAKE PEDAL ... ADJUSTMENT 0.2
Incl
354014 10 BRAKE PEDAL SHAFT BUSHING ... REPLACEMENT 0.6
Incl

SERVICE BRAKE 35
SERVICE BRAKES /7
OPERATION
CR
CODE DESCRIPTION
354052 10 PROPORTIONING VALVE ... REPLACEMENT —
Incl
Brake system air bleeding

354055 10 PCRV (PRESSURE CONTROL RETURN VALVE) ... REPLACEMENT 1.1
Incl
Brake system air bleeding
3545 ANTI-SKID GENERAL FRM0350354511002
354510 10 MODULATOR ASSY ... REPLACEMENT —

Incl
Air bleeding
354520 10 HYDRAULIC UNIT ASSY ... REPLACEMENT 1.5
Incl
Air bleeding
A9 ... Inspection by P DT 1.0
3582 SWITCH GENER L FRM0350358211002
358201 10 STOP LAMP SWITCH ... REPL CEMENT 0.3

358201 40 STOP LAMP SWITCH ... ADJUSTMENT 0.2
358303 84 SPEED SENSOR (ABS) (F ONT) ... REPLACEMENT (One side) 0.4

358303 86 SPEED SENSOR (ABS) (REAR) ... REPLACEMENT (One side) 0.5

358305 10 PE AL STROKE SENSOR ... REPLACEMENT —
A9 ... Inspection by PADT

358501 10 ANTI-SKID (ABS) CONTROL UNIT ... REPLACEMENT —

Incl
Air bleeding
A9 ... Inspection by PADT

35 SERVICE BRAKE
/8 SERVICE BRAKES
NOTE

PARKING BRAKE 36
Content /1
36 PARKING BRAKE
PARKING BRAKES ..................................................................... 36/3

36 PARKING BRAKE
DOIQF036R12001

PARKING BRAKE 36
PARKING BRAKES /3
PARKING BRAKES FRM0360361011003
OPERATION
CR
CODE DESCRIPTION
3610 PARKING CONTROL GENERAL
361010 10 PARKING BRAKE LEVER ASSY ... REPLACEMENT 0.4
Incl
Parking brake switch-adjustment
361050 10 REAR PARKING BRAKE CABLE ASSY ... REPLACEMENT (One piece) 0.9
Incl
Parking lever assy-R&I

368201 10 PARKING SWITCH ... REPLACEMENT 0.3

36 PARKING BRAKE
/4 PARKING BRAKES
NOTE

STEERING 37
Content /1
37 STEERING
STEERING ............................................................................... 37/4

37 STEERING
DOIQF037R12001

STEERING 37
DOIQF037R12002

37 STEERING
/4 STEERING
STEERING FRM0370371011001
OPERATION
CR
CODE DESCRIPTION
3710 STEERING WHEEL GENERAL
371010 10 STEERING WHEEL ASSY ... REPLACEMENT 0.3
371012 10 STEERING WHEEL HORN PAD ... REPLACEMENT 0.3
371012 25 STEERING WHEEL HORN PAD ... REPAIR 0.4
3720 STEERING SHAFT & COLUMN GENERAL FRM0370372011001
372010 10 STEERING SHAFT ASSY ... REPLACEMENT 1.0

Incl
Steering wheel assy-R&I
Lever/column switch assy-R&I
372050 10 STEERING SHAFT JOINT ASSY ... REPLACEMENT 1.3
372070 10 STEERING COLUMN COVER ASSY ... REPLACEMENT 0.3
372090 10 STEERING LOCK ... REPLACEMENT 1.0
Incl
Steering shaft assy-R&I
3740 STEERING GEAR BOX GENER L (POWER) FRM0370374011001
374050 10 STEE ING GEAR SSY ( CK & PINION) ... REPLACEMENT 2.1
Incl
Steering wheel centering-adjustment
Toe-in-adjustment
Air bleeding
374050 20 STEE ING GEAR ASSY ( ACK & PINION) ... OVERHAUL —
Incl
Steering gear assy-R&I
374055 10 STEERING GEAR BOX PIPING ... REPLACEMENT 1.5
Incl
Air bleeding
374058 10 STEERING GEAR BOX BELLOWS ... REPLACEMENT (One side) 1.0
Incl
Tie rod end-R&I
Toe-in-adjustment
3750 POWER STEERING SOURCE GENERAL FRM0370375011001
375010 10 POWER STEERING OIL PUMP ASSY ... REPLACEMENT 0.9

Incl
Air bleeding
375010 20 POWER STEERING OIL PUMP ASSY ... OVERHAUL 1.5
375020 10 POWER STEERING OIL RESERVOIR ASSY ... REPLACEMENT 0.5
375051 10 POWER STEERING PRESSURE HOSE ... REPLACEMENT 0.6
375054 10 POWER STEERING RETURN HOSE ... REPLACEMENT 0.5
375057 10 POWER STEERING SUCTION HOSE ... REPLACEMENT 0.5
375061 10 POWER STEERING RETURN PIPE ... REPLACEMENT 0.6
375066 10 POWER STEERING OIL COOLER TUBE ... REPLACEMENT 0.7

STEERING 37
STEERING /5
OPERATION
CR
CODE DESCRIPTION
3760 STEERING LINKAGE GENERAL FRM0370376011001
376041 10 TIE ROD ... REPLACEMENT (One side) 1.4

Incl
Toe-in-adjustment
376042 10 TIE ROD END ... REPLACEMENT (One side) 0.6
Incl
Toe-in-adjustment
378222 10 POWER STEERING OIL PRESSURE SWITCH ... REPLACEMENT 0.5

37 STEERING
/6 STEERING
NOTE

BODY (PARTS) 42
Content /1
42 BODY (PARTS)
BODY .................................................................................... 42/7

42 BODY (PARTS)
DOIQF042R12001

BODY (PARTS) 42
DOIQF042R12002

42 BODY (PARTS)
DOIQF042R12003

BODY (PARTS) 42
DOIQF042R12004

42 BODY (PARTS)
DOIQF042R12005

BODY (PARTS) 42
BODY /7
BODY FRM0420421011001
OPERATION
CR
CODE DESCRIPTION
4210 BODY SHELL GENERAL
421073 10 FRONT END MODULE... REPLACEMENT 1.6
Incl
Front bumper-R&I
4220 LOOSE PANEL GENERAL FRM0420422011003
422022 10 FRONT FENDER PANEL ... REPLACEMENT (One side) 0.6

Incl
Fender shield-R&I
422022 40 FRONT FENDER PANEL ... ADJUSTMENT (One side) 0.2
422025 10 FRONT FENDER SPLASH SHIELD PANEL ... REPLACEMENT (One side) 0.3
422031 10 REAR SPLASH SHIELD 0.3
4231 FRONT WINDOW GENER L FRM0420423111001
423121 10 FRONT WINDOW GL SS ... REPL CEMENT 2.7

Incl
Window moulding-R&I
Weatherstrip- &I
4232 REAR WINDOW GENE AL FRM0420423211001
423221 10 REAR WINDOW GLASS ... EPLACEMENT 2.5

Incl
Window moulding- &I

4241 FRONT OOR GENERAL FRM0420424111001
424110 00 FRONT OOR ASSY ... REMOVAL AND INSTALLATION (One side) 0.5
Incl
Alignment-adjustment
424110 40 FRONT OOR ASSY ... ADJUSTMENT (One side) 0.3
424111 10 FRONT DOOR PANEL ... REPLACEMENT (One side) 1.4
Incl
Door panel installation-R&I

424112 10 FRONT DOOR SASH ... REPLACEMENT 0.4
Incl
Door trim-R&I
424113 10 FRONT DOOR HINGE ... REPLACEMENT 0.9
Incl
424114 10 FRONT DOOR CHECK ... REPLACEMENT (One side) 0.6
Incl
Door trim-R&I
424121 10 FRONT DOOR GLASS ... REPLACEMENT (One side) 0.5
Incl
Door trim-R&I
Door glass-adjustment
42 BODY (PARTS)
/8 BODY
OPERATION
CR
CODE DESCRIPTION
424121 40 FRONT DOOR GLASS ... ADJUSTMENT (One side) 0.3
Incl
Door trim-R&I
424125 10 FRONT DOOR RUN CHANNEL ... REPLACEMENT (One side) 0.4
424131 10 FRONT DOOR WEATHERSTRIP (BODY SIDE) ... REPLACEMENT (One side) 0.3
424132 10 FRONT DOOR WEATHERSTRIP (DOOR SIDE) ... REPLACEMENT (One side) 0.2
424141 10 FRONT DOOR LATCH (LOCK) ... REPLACEMENT (One side) 0.6
Incl
Door trim-R&I
424141 40 FRONT DOOR LATCH (LOCK) ... ADJUSTMENT (One side) 0.5
424142 10 FRONT DOOR STRIKER ... REPLACEMENT (One side) 0.2
424142 40 FRONT DOOR STRIKER ... ADJUSTMENT (One side) 0.2
424143 10 FRONT DOOR LOCK CYLINDER ... REPLACEMENT (One side) 0.6
Incl
Door trim-R&I
424144 10 FRONT DOOR OUTSIDE H NDLE ... REPL CEMENT (One side) 0.3
Incl
Door trim- &I
Outer handle-adjustment
424145 10 FRONT DOOR INSIDE HANDLE COVER ... REPLACEMENT (One side) 0.4
424149 10 FRONT DOOR OPENER CABLE ... REPLACEMENT (One side) 0.4
Incl
oor trim-R&I
424161 10 FRONT OOR REGULATOR ... REPLACEMENT (One side) 0.6
Incl
oor trim-R&I
oor glass-adjustment
4242 REAR DOOR GENERAL FRM0420424211001
424210 00 REAR DOOR ASSY ... REMOVAL AND INSTALLATION (One side) 0.4
Incl
424210 40 REAR DOOR ASSY ... ADJUSTMENT (One side) 0.3
424211 10 REAR DOOR PANEL ... ADJUSTMENT (One side) 1.3
Incl
Door panel installation parts-R&I
424212 10 REAR DOOR SASH ... REPLACEMENT (One side) 0.8
Incl
Door trim-R&I
424213 10 REAR DOOR HINGE ... REPLACEMENT (One side) 0.4
Incl
424214 10 REAR DOOR CHECK ... REPLACEMENT (One side) 0.5

BODY (PARTS) 42
BODY /9
OPERATION
CR
CODE DESCRIPTION
Incl
Door trim-R&I
424221 10 REAR DOOR GLASS ... REPLACEMENT (One side) 0.6
Incl
Door trim-R&I
424221 40 REAR DOOR GLASS ... ADJUSTMENT (One side) 0.4
Incl
Door trim-R&I
424225 10 REAR DOOR RUNCHANNEL ... REPLACEMENT (One side) 0.4
Incl
Door trim-R&I
424231 10 REAR DOOR WEATHERSTRIP (BODY) ... REPLACEMENT (One side) 0.3
424232 10 REAR DOOR WEATHERSTRIP (DOOR) ... REPLACEMENT (One side) 0.2
424241 10 REAR DOOR LATCH ... REPL CEMENT (One side) 0.5
Incl
Door trim-R&I
424241 40 REAR DOOR LATCH ... DJUSTMENT (One side) 0.3
Incl
Door trim- &I

424242 10 REAR DOOR ST IKER ... EPLACEMENT (One side) 0.2
424242 40 REAR DOOR ST IKER ... ADJUSTMENT (One side) 0.2
424244 10 REAR OOR OUTSIDE HANDLE ... REPLACEMENT (One side) 0.3
424245 10 REAR OOR INSIDE HANDLE ... REPLACEMENT (One side) 0.4
Incl
oor trim-R&I
Inner handle-adjustment
424249 10 REAR (SLIDE) DOOR OPENER CABLE ... REPLACEMENT (One side) 0.4
424261 10 REAR DOOR REGULATOR ... REPLACEMENT (One side) 0.5
Incl
Door trim-R&I
424291 10 STATIONARY WINDOW GLASS ... REPLACEMENT 0.4
424292 10 STATIONARY WINDOW WEATHESTRIP ...REPLACEMENT 0.4
4251 HOOD GENERAL FRM0420425111001
425110 00 HOOD ASSY ... REMOVAL & INSTALLATION 0.4

Incl
425110 40 HOOD ASSY ... ADJUSTMENT 0.3
425111 10 HOOD PANEL ... REPLACEMENT 0.5
Incl
425113 10 HOOD HINGE ... REPLACEMENT 0.6

42 BODY (PARTS)
/ 10 BODY
OPERATION
CR
CODE DESCRIPTION
Incl
Hood assy-R&I
425141 10 HOOD LATCH ... REPLACEMENT 0.3
425145 10 HOOD HOOK ... REPLACEMENT 0.3
Incl
425151 10 HOOD OPENER CABLE ... REPLACEMENT 0.7
Incl
Lock-adjustment
4252 TRUNK LID GENERAL FRM0420425211001
425210 00 TRUNK LID ASSY ... REMOVAL AND INSTALLATION 0.4

425211 10 TRUNK LID PANEL ... REPLACEMENT 0.9
Incl
Trunk lid assy-R&I
425213 10 TRUNK LID HINGE ... REPL CEMENT (One side) 0.7
425215 10 TRUNK LID GAS SPRING ... REPL CEMENT (One side) –
425216 10 TRUNK LID SP ING ... EPLACEMENT (One side) 0.2
425231 10 TRUNK LID WEATHE ST IP ... EPLACEMENT 0.3
425241 10 TRUNK LID LATCH ... EPLACEMENT 0.4
425242 10 TRUNK LID ST IKER ... EPLACEMENT 0.4
425243 10 TRUNK LID LOCK CYLINDER ... REPLACEMENT 0.3
425251 10 TRUNK LID OPENER CABLE ... REPLACEMENT 0.8
425252 10 TRUNK LID OPENER LEVER ... REPLACEMENT 0.6
425253 10 TRUNK LID STOPPER (TORSION BAR) 0.3
4253 FUEL FILLER LID GENERAL FRM0420425311001
425311 10 FUEL FILLER LID ... REPLACEMENT 0.2

425341 10 FUEL FILLER LID LATCH ... REPLACEMENT 0.3
425341 40 FUEL FILLER LID LATCH ... ADJUSTMENT 0.2
425351 10 FUEL FILLER LID OPENER CABLE ... REPLACEMENT 0.8
425352 10 FUEL FILLER LID OPENER LEVER ... REPLACEMENT 0.4
428101 10 POWER WINDOW MOTOR (FRONT DOOR) ... REPLACEMENT (One side) 0.6
Incl
Door trim-R&I
428102 10 POWER WINDOW MOTOR (REAR DOOR) ... REPLACEMENT (One side) 0.6
Incl
Door trim-R&I
428111 10 DOOR LOCK ACTUATOR (FRONT DOOR) ... REPLACEMENT (One side) 0.6
Incl
Door trim-R&I
428112 10 DOOR LOCK ACTUATOR (REAR DOOR) ... REPLACEMENT (One side) 0.5

BODY (PARTS) 42
BODY / 11
OPERATION
CR
CODE DESCRIPTION
Incl
Door trim-R&I
428201 10 POWER WINDOW SWITCH (MAIN) ... REPLACEMENT 0.2

428202 10 POWER WINDOW SWITCH (SUB) ... REPLACEMENT (One side) 0.2
428501 10 DOOR LOCK CONTROL UNIT (AUTO) ... REPLACEMENT 0.2

4289 ELECTRICAL EQUIPMENT (OTHERS) GENERAL FRM0420428911001
428921 10 ALARM SYSTEM CONTROL UNIT (WITH TRANSMITTER) ... REPLACEMENT 0.3

42 BODY (PARTS)
/ 12 BODY
NOTE

BODY PAINT 42A
Content /1
42A BODY PAINT

GRAPHICAL ILLUSTRATIONS ........................................................ 42A/2
BODY PAINT ............................................................................ 42A/3

INSTRUCTION FOR PAINT WORK ................................................ 42A/3
1. OPERATION CODE ............................................................... 42A/3
Selection of Proper Position Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...........42A/3
Selection of Proper Work Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...........42A/3
2. CONDITION CODE ............................................................... 42A/4
Selection of Proper Position Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...........42A/4
Selection of A Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...........42A/4

42A BODY PAINT
GRAPHICAL ILLUSTRATIONS FRM42AGRAPH007
DOIQF42AR12001

BODY PAINT 42A
BODY PAINT /3
BODY PAINT FRM42APAINT006
INSTRUCTION FOR PAINT WORK

In preparing the paint work warranty claim form, please refer to this group to ensure correct prepar-ation
of the warranty claim form.
1. OPERATION CODE
The paint work operation code consists of 6–digit position code and 2–digit work code in the same
manner as the general operation code.
Selection of Proper Position Code
1. To find the position code of outer panel for major paint work, please select a proper position code
from among the position codes shown in the attached illustrations.
2. If the repair area extends over two or more panels, select the position codes of respective panels and
enter the actual cost in the warranty claim form by positions.
Even in this case, however, enter the actual cost separately for each of work performed on the part
shown in Table 1
Table 1
No. Position name Position code
1 Front pillar 421023
2 Rear pillar 421033
3 Quarter panel 421034
4 Side sill 421044
5 Roof 421051
6 Fender 422022
7 Front door 424111
8 Front door sash 424112
9 Rear door 424211
10 Rear door sash 424212
11 Tailgate 424311
12 Trunk lid 425211
13 Hood 425111
14 Fuel filler lid 425311
15 Rear view mirror 513010
16 Front bumper 514110
17 Rear bumper 514210
18 Side protector moulding 516231
Selection of Proper Work Code
The work codes to be used in combination with the above position codes are as follows:
71 or 1T Paint work (without position specified)

2T Painting (R.H side of car or vehicle)
3T Painting (L.H side of car or vehicle)
4T Under coating (Anti-rust for under floor)
Combination of position code and work code is as follows:

42A BODY PAINT
/4 BODY PAINT
Example 1 (Right front door painting: code 424111–2T)

424111 Position code for front door
2T Work code for painting right side
Example 2 (Left rear door painting: code 424211–3T)
424211 Position code for rear door
3T Work code for painting left side
Example 3 (FOR FRONT BUMPER PAINTING : 514110–1T)
514110 Position code for front bumper
1T Work code for painting
Example 4 (FOR REAR BUMPER PAINTING : 514210–1T)
514210 Position code for rear bumper
1T Work code for painting
2. CONDITION CODE
The paint failure condition code must be entered in combination of 6 digit position code and A code in the
same manner as the general failure condition code. (Normally, entry of B code or C code is not required.)
Selection of Proper Position Code

Example : Runs on right front door and foreign material on roof.
a) Front door repair General claim

Condition code 424111 PD
Repair code 424111 2T
b) Roof repair General claim
Condition code 421051 PF
Repair code 421051 1T
Selection of A Code
Select only A code from the following table to obtain the failure code for paint work.
Failure condition A code

Priming coat defect PA
Thin paint PB
Seeding PC
Runs PD
Scratch PE
Adhesion of foreign materials PF
Color mismatching PR
Orange peel PS
Peeling PT
Discoloration PG
Fading PH
Uneven PJ
Blister PK
Rust spot PM

BODY PAINT 42A
BODY PAINT /5
Failure condition A code

Perforation PN
Other paint defects PX
Rust (Hem/Joint) PP
Rust contact PQ
Example : (Roof thin paint : 421051–PB)
421051 Position code for roof
PB A code for thin paint

42A BODY PAINT
/6 BODY PAINT
NOTE

EXTERIOR 51
Content /1
51 EXTERIOR
EXTERIOR ............................................................................... 51/5

51 EXTERIOR
DOIQF051R12001

EXTERIOR 51
DOIQF051R12002

51 EXTERIOR
DOIQF051R12003

EXTERIOR 51
EXTERIOR /5
EXTERIOR FRM0510511111002
OPERATION
CR
CODE DESCRIPTION
5111 FRONT WINDOW WIPER GENERAL
511120 10 FRONT WINDOW WIPER ARM ASSY ... REPLACEMENT (One side) 0.2
511130 10 FRONT WINDOW WIPER BLADE ASSY ... REPLACEMENT (One side) 0.2
511140 10 FRONT WINDOW WIPER LINK ASSY ... REPLACEMENT (One side) 0.7
Incl
Wiper arm-R&I adjustment
5112 REAR WINDOW WIPER GENERAL FRM0510511211002
511220 10 REAR WINDOW WIPER ARM ASSY ... REPLACEMENT —

511230 10 REAR WINDOW WIPER BLADE ASSY ... REPLACEMENT —
511232 10 REAR WINDOW WIPER BLADE RUBBER ... REPLACEMENT —
5121 FRONT WINDOW WASHER GENERAL FRM0510512111002
512121 10 FRONT WINDOW W SHER T NK ... REPL CEMENT 0.4

512131 10 FRONT WINDOW W SHER NOZZLE ... REPL CEMENT (One side) 0.2
5122 REAR WINDOW W SHER GENER L FRM0510512211002
512231 10 REAR WINDOW W SHER NOZZLE ... REPL CEMENT (One side) 0.2
5130 REAR VIEW GENE AL FRM0510513011003
513010 10 REAR VIEW MI OR ASSY ... EPLACEMENT (One side) 0.3

5141 FRONT BUMPER GENE AL FRM0510514111003
514110 10 FRONT BUMPER ASSY ... EPLACEMENT 0.6

514121 10 FRONT BUMPER FACE ... REPLACEMENT 0.8
Incl
Front bumper assy-R&I
514125 10 FRONT BUMPER REINFORCEMENT (BEAM) 0.7
Incl
514175 10 FRONT BUMPER GRILLE (UPPER) ... REPLACEMENT 0.7
Incl
514176 10 FRONT BUMPER GRILLE (LOWER) ... REPLACEMENT 0.7
Incl
5142 REAR BUMPER GENERAL FRM0510514211002
514210 10 REAR BUMPER ASSY ... REPLACEMENT 0.7
514221 10 REAR BUMPER FACE ... REPLACEMENT 0.8
Incl
Rear bumper assy-R&I
514231 10 REAR BUMPER (INERTIA ABSORBER) STAY ... REPLACEMENT 0.8
5150 AERO PARTS GENERAL FRM0510515011002
515029 00 TRUNK LID SPOILER ASSY ... REMOVAL AND INSTALLATION 1.1

51 EXTERIOR
/6 EXTERIOR
OPERATION
CR
CODE DESCRIPTION
Incl
Cleaning
515029 10 TRUNK LID SPOILER ASSY ... REPLACEMENT 0.4
Incl
5150 AERO PARTS GENERAL FRM0510515011003
515014 00 FRONT SKIRT ASSY ... REMOVAL AND INSTALLA ION 1.3
Incl
Cleaning
515014 10 FRONT SKIRT ASSY ... REPLACEMENT 0.6
Incl
515029 00 TRUNK LID SPOILER SSY ... REMOV L ND INST LLATION 1.1
Incl
Cleaning
515029 10 TRUNK LID SPOILER SSY ... EPL CEMENT 0.4
Incl
515030 00 REAR SKIRT ASSY ... EMOVAL AND INSTALLATION 1.3
Incl
Cleaning
515030 10 REAR SKIRT ASSY ...REPLACEMENT 0.4
Incl
515065 00 SIDE SILL MOULDING ASSY ... REMOVAL AND INSTALLATION (One Side) 1.4
Incl
Cleaning
515065 10 SIDE SILL MOULDING ASSY ... REPLACEMENT (One Side) 0.6
Incl
5161 GRILL & GARNISH GENERAL FRM0510516111002
516104 10 FRONT DELTA COVER ... REPLACEMENT 0.2

516105 10 REAR DELTA COVER ... REPLACEMENT 0.2
516116 10 FRONT DECK GARNISH ... REPLACEMENT 0.3
516120 10 REAR PLATE GARNISH ... REPLACEMENT 0.2
5162 MOULDING GENERAL FRM0510516211002
516233 10 DRIP RAIL MOULDING ... REPLACEMENT (One side) 0.4

516252 10 FRONT DOOR BELT LINE MOULDING ... REPLACEMENT (One side) 0.4
516262 10 REAR DOOR BELT LINE MOULDING ... REPLACEMENT (One side) 0.4

EXTERIOR 51
EXTERIOR /7
OPERATION
CR
CODE DESCRIPTION
5164 MARK & EMBLEM GENERAL FRM0510516411002
516421 10 REAR MARK ... REPLACEMENT (One piece) 0.2

5170 EXTERIOR MISCELLANEOUS GENERAL FRM0510517011002
517011 10 FRONT MUDGUARD ... REPLACEMENT (One side) —

517015 10 FRONT MUDGUARD ... REPLACEMENT (One side) —
518101 10 WIPER MOTOR (FRONT WINDOW) ... REPLACEMENT 0.7

518111 10 WASHER MOTOR (FRONT WINDOW) ... REPLACEMENT 0.4
518201 10 WIPER SWITCH (FRONT WINDOW) ... REPLACEMENT 0.6

Incl
Column switch – R&I
518241 10 REMOTE CONTROL MIRROR SWITCH ... REPL CEMENT 0.2

51 EXTERIOR
/8 EXTERIOR
NOTE

INTERIOR 52
Content /1
52 INTERIOR
INTERIOR ................................................................................ 52/10

52 INTERIOR
DOIQF052R12001

INTERIOR 52
DOIQF052R12002

52 INTERIOR
DOIQF052R12003

INTERIOR 52
DOIQF052R12004

52 INTERIOR
DOIQF052R12005

INTERIOR 52
DOIQF052R12006

52 INTERIOR
DOIQF052R12007

INTERIOR 52
DOIQF052R12008

52 INTERIOR
/ 10 INTERIOR
INTERIOR FRM0520521111002
OPERATION
CR
CODE DESCRIPTION
5211 FRONT SEAT GENERAL (DRIVER)
521120 10 FRONT SEAT CUSHION ASSY ... REPLACEMENT 0.5
Incl
Seat assy-R&I
521121 10 FRONT SEAT CUSHION COVER ... REPLACEMENT 0.9
Incl
Seat cushion-R&I
521130 10 FRONT SEAT BACK ASSY ... REPLACEMENT 0.5
Incl
Seat assy-R&I
521131 10 FRONT SEAT BACK COVER ... REPLACEMENT 1.1
Incl
Seat back-R&I
521141 10 FRONT SEAT HEAD RESTR INT ... REPL CEMENT 0.2
521152 10 FRONT SEAT SLIDE DJUSTMENT ... REPL CEMENT 0.7
Incl
Seat assy- &I
5212 FRONT SEAT GENE AL (PASSENGER) FRM0520521211002
521220 10 FRONT SEAT CUSHION ASSY ... EPLACEMENT 0.5

Incl
Seat assy-R&I
521221 10 FRONT SEAT CUSHION COVER ... REPLACEMENT 0.9
Incl
Seat cushion-R&I
521230 10 FRONT SEAT BACK ASSY ... REPLACEMENT 0.5
Incl
Seat assy-R&I
521231 10 FRONT SEAT BACK COVER ... REPLACEMENT 1.1
Incl
Seat back-R&I
521241 10 FRONT SEAT HEAD RESTRAINT ... REPLACEMENT 0.2
521252 10 FRONT SEAT SLIDE ADJUSTMENT ... REPLACEMENT 0.7
5215 REAR SEAT GENERAL (SECOND) FRM0520521511002
521520 10 REAR SEAT CUSHION ASSY ... REPLACEMENT (One piece) 0.2
521521 10 REAR SEAT CUSHION COVER ... REPLACEMENT (One piece) 1.1
Incl
Seat cushion-R&I
521530 10 REAR SEAT BACK ASSY ... REPLACEMENT (One piece) 0.4
521531 10 REAR SEAT BACK COVER ... REPLACEMENT (One piece) 1.6
Incl
Seat back-R&I

INTERIOR 52
INTERIOR / 11
OPERATION
CR
CODE DESCRIPTION
521533 10 REAR SEAT BACK (Side) ... REPLACEMENT 0.3
521553 10 REAR SEAT SLIDE ADJUSTER TORQUE CABLE ... REPLACEMENT 0.3
521541 10 REAR SEAT HEAD RESTRAINT 0.2
5220 SEAT BELT GENERAL FRM0520522011002
522010 10 FRONT SEAT BELT ASSY (DRIVER) ... REPLACEMENT (One piece) 0.4
522020 10 FRONT SEAT BELT ASSY (PASSENGER) ... REPLACEMENT (One piece) 0.4
522050 10 REAR SEAT BELT ASSY ... REPLACEMENT (One piece) 0.6
522080 10 REAR SEAT BELT ASSY (CENTRE) ... REPLACEMENT (One piece) 0.3
5231 INSTRUMENT PANEL GENERAL FRM0520523111002
523110 10 INSTRUMENT PANEL ASSY ... REPLACEMENT 2.0

Incl

523111 10 INSTRUMENT PANEL ... REPLACEMENT 2.8
Incl
Instrument panel and related parts-R&I

523114 10 INSTRUMENT P NEL METER HOOD (COVER) ... REPLACEMENT 0.4
523130 10 INSTRUMENT P NEL GLOVE BOX (COVER) ... REPLACEMENT 0.2
523132 10 INST UMENT PANEL GLOVE BOX LOCK & STRIKER ... REPLACEMENT 0.2
523150 10 INST UMENT PANEL ACCESSORY BOX ... REPLACEMENT 0.5
523171 10 KNEE P OTECTOR ... EPLACEMENT 0.2
5232 CENTER CONSOLE GENE AL FRM0520523211002
523225 10 CUP HOL ER ... REPLACEMENT 0.2

5233 FLOOR CONSOLE GENERAL FRM0520523311002
523310 10 FLOOR CONSOLE ... REPLACEMENT 0.3

5241 CARPET & HEADLINING GENERAL FRM0520524111002
524101 10 HEADLINING ... REPLACEMENT 0.6

524110 10 FLOOR CARPET (MAT) ASSY ... REPLACEMENT (All) 1.0
524113 10 TRUNK (CARGO) FLOOR CARPET (MAT) ... REPLACEMENT 0.2
5242 TRIM GENERAL FRM0520524211002
524221 10 REAR SHELF TRIM (CENTER) ... REPLACEMENT 0.6

524225 10 REAR END TRIM COVER ... REPLACEMENT 0.2
524226 10 TRUNK SIDE TRIM ... REPLACEMENT 0.2
524227 10 TRUNK LID TRIM ... REPLACEMENT 0.3
524231 10 FRONT PILLAR TRIM ... REPLACEMENT (One side) 0.2
524232 90 CENTER PILLAR TRIM (UPPER) ... REPLACEMENT (One side) 0.3
524232 91 CENTER PILLAR TRIM (LOWER) ... REPLACEMENT 0.2
524233 10 REAR PILLAR TRIM ... REPLACEMENT (One piece) 0.3
524236 10 SCUFF PLATE (FRONT) ... REPLACEMENT (One piece) 0.2
524237 10 SCUFF PLATE (REAR) ... REPLACEMENT (One piece) 0.2
524254 10 FRONT SIDE SILL TRIM ... REPLACEMENT 0.3
524255 10 REAR SIDE TRIM ... REPLACEMENT 0.3

52 INTERIOR
/ 12 INTERIOR
OPERATION
CR
CODE DESCRIPTION
524260 10 FRONT DOOR TRIM ASSY ... REPLACEMENT (One piece) 0.4
524270 10 REAR DOOR TRIM ASSY ... REPLACEMENT (One piece) 0.4
5250 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) FRM0520525011002
525000 90 SRS SYSTEM ... INSPECTION AT 10 YRS 0.8

Incl
INSPECTION (SERVICE)
525010 10 SRS MODULE ... REPLACEMENT 0.6
Incl
525011 10 SRS CLOCK SPRING ... REPLACEMENT 0.8
Incl
525020 10 SRS MODULE (PASSENGER SIDE) ... REPLACEMENT 0.8
Incl
5270 INTERIOR MISCELL NEOUS P RTS FRM0520527011002
527052 10 SUNGLASS HOLDER ... REPL CEMENT 0.2

527055 10 JACK SET ... EPL CEMENT 0.2
527056 10 TOOL SET ... EPLACEMENT 0.2
527074 10 ASSIST G IP ... EPLACEMENT (One piece) 0.2
527077 10 ROOM MI OR ... EPLACEMENT 0.2
527078 10 SUN VISOR & SUNSHADE ... REPLACEMENT (One side) 0.2
527081 10 FOOT REST ... REPLACEMENT 0.2
528321 10 SI E IMPACT SENSOR ... REPLACEMENT (One piece) —

Incl
528511 10 SRS CONTROL UNIT ... REPLACEMENT 0.4

Incl

Content /1
CHASSIS ELECTRICAL ................................................................. 54/8

DOIQF054R12001

DOIQF054R12002

DOIQF054R12003

DOIQF054R12004

DOIQF054R12005

DOIQF054R12006

/8 CHASSIS ELECTRICAL
CHASSIS ELECTRICAL FRM0540541011002
OPERATION
CR
CODE DESCRIPTION
5410 EXTERIOR LAMP GENERAL (FRONT)
541011 10 HEADLAMP UNIT ... REPLACEMENT (One piece) 0.4
541013 10 HEADLAMP BULB ... REPLACEMENT (One piece) 0.2
541032 10 FRONT TURN SIGNAL LAMP BULD... REPLACEMENT (One piece) 0.2
541040 10 FRONT SIDE TURN SIGNAL LAMP ASSY ... REPLACEMENT 0.3
541070 10 FRONT FOG LAMP ASSY ... REPLACMENT (One side) 0.6
5413 EXTERIOR LAMP GENERAL (REAR) FRM0540541311002
541301 10 EXTERIOR LAMP BULB ... REPLACEMENT 0.3

541310 10 REAR COMBINATION LAMP ASSY ... REPLACEMENT (One side) 0.3
541312 10 REAR COMBINATION LAMP BULB ... REPLACEMENT (One piece) 0.2
541320 10 TRUNK LID REAR COMBINATION LAMP ASSY ... REPLACEMENT 0.2
541350 10 LICENCE PLATE L MP SSY ... REPL CEMENT (One piece) 0.2
541390 10 HIGH MOUNT STOP L MP ... REPL CEMENT 0.3
541391 10 HIGH MOUNT STOP L MP BULB ... REPL CEMENT 0.2
5418 INTERIOR LAMP GENER L FRM0540541811002
541810 10 ROOM LAMP ASSY ... EPL CEMENT 0.2

541811 10 ROOM LAMP BULB ... EPLACEMENT 0.2
541812 10 ROOM LAMP LENS ... EPLACEMENT 0.2
541815 10 MAP LAMP ASSY ... EPLACEMENT 0.2
541816 10 MAP LAMP BULB ... EPLACEMENT 0.2
541817 10 MAP LAMP LENS ... REPLACEMENT 0.2
541830 10 CANGO ROOM (LUGGAGE COMPARTMENT) LAMP ASSY ... REPLACEMENT 0.2
541892 10 UTILITY BOX LAMP BULB ... REPLACEMENT 0.2
5420 METER & GAUGE GENERAL FRM0540542011002
542001 10 BULB FOR METER & GAUGE ... REPLACEMENT —

542010 10 COMBINATION METER ASSY ... REPLACEMENT 0.4
5427 PRINTED BOARD GENERAL FRM0540542711001
542710 10 METER PRINTED BOARD ASSEMBLE ... REPLACEMENT —

Incl
Combination lamp assy-R&I
542720 10 INDICATOR LAMP PRINTED BOARD ASSY REPLACEMENT... —
Incl
Combination lamp assy-R&I
5430 BATTERY GENERAL FRM0540543011002
543010 10 BATTERY ... REPLACEMENT (One piece) 0.3

A9 ... Test and Inspection 0.2

5435 WIRING HARNESS GENERAL FRM0540543511002
543501 10 FUSE REPLACEMENT... 0.2

543510 10 BATTERY CABLE REPLACEMENT... 0.5

CHASSIS ELECTRICAL /9
OPERATION
CR
CODE DESCRIPTION
543541 10 INSTRUMENT PANEL HARNESS ... REPLACEMENT 2.5
543542 10 FRONT WIRING HARNESS ... REPLACEMENT 1.1
543545 10 BODY / FLOOR HARNESS ... REPLACEMENT 4.4
543551 10 DOOR HARNESS ... REPLACEMENT (One piece) 0.4
543554 10 TRUNK LID LAMP HARNESS ... REPLACEMENT 0.2
543561 10 REMOTE CONTROL MIRROR HARNESS ... REPLACEMENT 0.3
543563 10 ENGINE CONTROL HARNESS ... REPLACEMENT 0.9
543565 10 FRONT END HARNESS ... REPLACEMENT 0.3
5440 WARNING EQUIPMENT GENERAL FRM0540544011002
544011 10 HORN ... REPLACEMENT (One piece) 0.6

5450 SOUND EQUIPMENT GENERAL FRM0540545011004
545011 10 RADIO ... REPLACEMENT 0.4

545032 10 REAR SPEAKER ... REPL CEMENT (One piece) 0.6
545033 10 DOOR SPEAKER ... REPL CEMENT (One side) 0.4
545052 10 ANTENNA POLE / ROD ... REPL CEMENT 0.2
545057 10 BEE STING ... REPL CEMENT 0.6
5470 MISCELLANEOUS ELECT IC L EQUIPMENT GENERAL
FRM0540547011002
547020 84 CIGA ETTE LIGHTER ASSY / POWER SOURCE ... REPLACEMENT 0.5
547020 86 CIGA ETTE LIGHTER ASSY / POWER SOURCE (REAR) ... REPLACEMENT 0.5
547055 10 USB PORT ... EPLACEMENT 0.4
547092 10 IMMOBILIZER TRANSPONDER ... REPLACEMENT 0.6
547094 10 BO Y CONTROL MODULE ... REPLACEMENT 0.6
548201 10 OOR SWITCH ... REPLACEMENT (One piece) 0.2

548205 DOOR LOCK WARNING SWITCH ... REPLACEMENT 0.2
548206 10 HOOD SWITCH ... REPLACEMENT 0.2
548211 10 COLUMN (COMBINATION), LEVER SWITCH ... REPLACEMENT 0.5
Incl

Steering column cover assy-R&I
548211 25 COLUMN (COMBINATION), LEVER SWITCH ... REPAIR 0.5
548215 10 HAZARD WARNING LAMP SWITCH ... REPLACEMENT 0.3
548221 10 LIGHTING SWITCH ... REPLACEMENT 0.6
Incl
Column switch-R&I
548231 10 FOG LAMP SWITCH ... REPLACEMENT 0.3
548232 10 REAR FOG LAMP SWITCH ... REPLACEMENT 0.3
548235 10 DEFOGGER SWITCH ... REPLACEMENT 0.3
548239 10 ALARM RESET SWITCH ... REPLACEMENT 0.3
548261 10 IGNITION SWITCH ... REPLACEMENT 0.4
548266 10 HEADLAMP LEVELING SWITCH 0.2
/ 10CHASSIS ELECTRICAL
OPERATION
CR
CODE DESCRIPTION
548281 10 COLUMN SWITCH LEVER CAP ... REPLACEMENT (One side) 0.2
548282 10 ESC SWITCH ... REPLACEMENT 0.3
548201 10 DOOR SWITCH ... REPLACEMENT (One piece) 0.2

548206 10 HOOD SWITCH ... REPLACEMENT 0.2
548211 10 COLUMN (COMBINATION), LEVER SWITCH ... REPLACEMENT 0.5
Incl
Steering column cover assy-R&I
548211 25 COLUMN (COMBINATION), LEVER SWITCH ... REPAIR 0.5
548215 10 HAZARD WARNING LAMP SWITCH ... REPLACEMENT 0.3
548221 10 LIGHTING SWITCH ... REPLACEMENT 0.6
Incl
Column switch-R&I
548231 10 FOG LAMP SWITCH ... REPL CEMENT 0.3
548235 10 DEFOGGER SWITCH ... REPL CEMENT 0.3
548239 10 ALARM RESET SWITCH ... REPL CEMENT 0.3
548261 10 IGNITION SWITCH ... EPL CEMENT 0.4
548266 10 HEADLAMP LEVELING SWITCH 0.2
548281 10 COLUMN SWITCH LEVER CAP ... REPLACEMENT (One side) 0.2
548345 10 REVE SE SENSOR ... EPLACEMENT (One side) 0.9

Incl
Rear bumper-R&I
548346 10 RAIN LIGHT SENSOR ... REPLACEMENT 0.3
548349 10 SOLAR SENSOR ... REPLACEMENT 0.2
548401 10 TURN & HAZARD FLASHER UNIT ... REPLACEMENT 0.2

548412 10 HEADLAMP LIGHTING RELAY ... REPLACEMENT 0.2
548421 10 FOG LAMP RELAY ... REPLACEMENT 0.2
548471 10 DEFOGGER RELAY ... REPLACEMENT 0.2
548533 10 ALARM CONTROL UNIT ... REPLACEMENT 0.2

848578 10 REVERSE SENSOR CONTROL UNIT ... REPLACEMENT 0.3
548901 10 RHEOSTAT ... REPLACEMENT 0.4

548922 10 TRANSMITTER ASSY ... REPLACEMENT 0.2
548923 10 TRANSMITTER CASING ... REPLACEMENT 0.2
548924 10 SIREN ASSY ... REPLACEMENT 0.2
548930 25 KEY ALARM RE-PROGRAMMING ... REPAIR 0.2

Content /1

GRAPHICAL ILLUSTRATIONS ........................................................ 55/2
HEATER, AIR CONDITIONER & VENTILATION .................................... 55/5

DOIQF055R12001

DOIQF055R12002

DOIQF055R12003

HEATER, AIR CONDITIONER & VENTILATION /5
HEATER, AIR CONDITIONER & VENTILATION FRM0550550011002
OPERATION
CR
CODE DESCRIPTION
550000 90 REFRIGERANT CHARGE, AIR CONDITIONER 0.5
5511 HEATER UNIT GENERAL (FRONT) FRM0550551111002
551111 10 HEATER CORE ... REPLACEMENT 2.2

Incl
In-panel-R&I
551110 10 FRONT HEATER ASSY ... REPLACEMENT 2.2
Incl
In-panel-R&I
551120 10 BLOWER ASSY ... REPLACEMENT 2.1
Incl
In-panel-R&I
5515 AIR CONDITIONER UNIT GENER L (FRONT) FRM0550551511004
551510 10 AIR CONDITIONER UNIT ... REPL CEMENT 2.6

Incl
Refrigerant charge
In-panel assy... &I
551511 10 COOLER EVAPO ATOR ASSY (F ONT) ... REPLACEMENT 2.6
Incl
Refrigerant charge
In-panel assy... &I
551512 10 EXPANSION VALVE ... REPLACEMENT 1.0
Incl
Refrigerant charge
551514 10 COOLER THERMISTOR ... REPLACEMENT 2.6
Incl
Refrigerant charge
In-panel assy... R&I
551515 10 AMPLIFIER ... REPLACEMENT 0.3
551522 10 DRAIN HOSE ... REPLACEMENT 0.2
551525 10 FILTER ... REPLACEMENT 0.2
5516 AIR CONDITIONER UNIT ASSY (REAR) FRM0550551611002
551610 10 AIR CONDITIONER (REAR) ... REPLACEMENT 0.5

551611 10 COOLER EVAPORATOR ASSY (REAR) ... REPLACEMENT 0.5
551622 10 DRAIN HOSE (REAR)... REPLACEMENT 0.7
5520 AIR DUCT & VENTILATION GENERAL FRM0550552011002
552012 10 DEFROSTER NOZZLE ... REPLACEMENT 2.5

552015 10 SIDE DEFROSTER DUCT ... REPLACEMENT 2.5
552020 10 VENTILATION DUCT GENERAL ... REPLACEMENT 2.5
552068 10 VENTILATOR WEATHERSTRIP (NOZZLE) CTR ... REPLACEMENT 0.2
552069 10 VENTILATOR WEATHERSTRIP (NOZZLE) SIDE ... REPLACEMENT (One side) 0.2

/ 6HEATER, AIR CONDITIONER & VENTILATION
OPERATION
CR
CODE DESCRIPTION
5531 AIR CONDITIONER COMPRESSOR GENERAL FRM0550553111002
553110 10 COMPRESSOR ASSY ... REPLACEMENT 1.0

Incl
Refrigerant charge
5532 AIR CONDITIONER CONDENSER GENERAL FRM0550553211003
553210 10 FRONT CONDENSER ASSY ... REPLACEMENT 1.1

Incl
Refrigerant charge
5540 CONTROL SYSTEM GENERAL FRM0550554011002
554010 10 HEATER / AIR-COND CONTROL ASSY ... REPLACEMENT 0.3

5555 PIPING GENERAL (COOLER) FRM0550555511002
555511 10 COOLER (DISCHARGE) HOSE ... REPLACEMENT (One piece) 0.8

Incl
Refrigerant charge
555512 10 COOLER (SUCTION) HOSE ... REPL CEMENT (One piece) 0.8
Incl
Refrigerant charge
555515 10 COOLER (SUCTION) PIPE ... EPLACEMENT 1.2
Incl
Refrigerant charge
555516 10 LIQUID PIPE (A) ... EPLACEMENT 0.8
Incl
Refrigerant charge
555517 10 LIQUID PIPE (B) ... REPLACEMENT 0.8
Incl
Refrigerant charge
555531 10 RECEIVER ... REPLACEMENT 1.1
558101 10 FRONT BLOWER MOTOR ... REPLACEMENT 0.4
558244 10 DUAL PRESSURE SWITCH ... REPLACEMENT 0.6
Incl
Refrigerant charge
558311 10 IN-CAR SENSOR ... REPLACEMENT —
Incl
Inspection
558313 10 PHOTO SENSOR ... REPLACEMENT
—
A9 ... Inspection
—
558321 10 AIR INTAKE / INLET SENSOR ... REPLACEMENT
—

HEATER, AIR CONDITIONER & VENTILATION /7
OPERATION
CR
CODE DESCRIPTION
A9 ... Inspection —
558335 10 AMBIENT SENSOR ... REPLACEMENT —
Incl
A9 ... Inspection —
558403 10 BLOWER MOTOR RELAY ... REPLACEMENT (One piece) 0.2

558411 10 CONDENSER FAN MOTOR RELAY ... REPLACEMENT (One piece) 0.2
558423 10 AIR COMPRESSOR RELAY ... REPLACEMENT 0.2
5586 SOLENOID VALVE GENERAL FRM0550558611002
558601 10 SOLENOID VALVE ... REPLACEMENT —

558901 10 HEATER BLOWER RESISTOR ... REPLACEMENT 0.3

/ 8. HEATER, AIR CONDITIONER & VENTILATION
NOTE

WORK CODE TABLE 100
Content /1
100 WORK CODE TABLE
WORK CODES TABLE ................................................................. 100/2

100 WORK CODE TABLE
/ 2. WORK CODES TABLE
WORK CODES TABLE FRM100WCODE301
Code WORK
00 Removal and installation
10 Replacement
15 Air bleeding
20 Overhaul
25 Repair
30 Inspection
40 Adjustment
70 Sheet metal
71 Painting
Code WORK
9A T/M Group WORK (A) or TRANS ER Group WORK (A)
9B T/M Group WORK (B) or TRANS ER Group WORK (B)
9C T/M Group WORK (C) or TRANS ER Group WORK (C)
9D T/M Group WORK (D) or TRANS ER Group WORK (D)
9E T/M Group WORK (E) or TR NSFER Group WORK (E)
9F T/M Group WORK (F) or TR NSFER Group WORK (F)
9G T/M Group WORK (G) or TR NSFER Group WORK (G)
9H T/M Group WORK (H)
9J T/M Group WORK (J)
9K T/M Group WO K (K)
9L T/M Group WO K (L)

FAILURE CODE 102
Content /1
102 FAILURE CODE

A - CODE ................................................................................ 102/2
B - CODE ................................................................................ 102/4
C - CODE ................................................................................ 102/8

102 FAILURE CODE
/2 A-CODE
A - CODE FRM102ACODE003
A CODE
POSITION
CODE FOR COMMON USE CODE FOR EXCLUSIVE USE
10 11 ENGINE Damaged, burned, seized, 81 Cavitation
worn, etc
12 LUBRICATION 10 Broken, Cracked 82 Lack of coolant
13 FUEL 11 Damaged, Torn 83 Slipping
14 COOLING 12 Burned, melted by heat 84 Smolder
15 INTAKE & EXHAUST 12A Burn mark 85 Overflow
16 ENGINE ELECTRICAL 13 Seized
17 ENGINE CONTROL 14 Stuck
15 Worn
16 Deformed, bent, distorted
16A Flat spot
17 Uneven contact
20 21 CLUTCH Water or oil leak, etc —
22 TRANSMISSION (M/T) 20 Water or coolant leak
23 TRANSMISSION (A/T) 21 Water penetration
24 PROPELLAR SHAFT 22 Oil leak
26 FRONT AXLE 22A Contamination
27 REAR AXLE 23 Lack of lubricant
30 31 WHEEL & TY E Defective insulation, etc —
32 POWER PLANT MOUN 26 Defective insulation, or
T short-circuited
33 FRONT SUSPENSION 27 Open circuit
34 REAR SUSPENSION 27A Circuit remain closed
35 SERVICE BRAKE Rusted, improperly plated,
etc
36 PARKING BRAKE 30 Rusted, corroded
37 STEERING 31 Improperly plated
32 Stained, discoloured
33 Flaked, peeled
33A Sharp edges
34 Deteriorated, fatigued
35 Improperly painted
35A Lack of gloss
Lack of parts, improperly
installed, etc.
40 Missing bolts or nut
41 Improperly tightened bolts
or nuts
41A Crossed thread
41B Bolts/nuts under torque
41C Bolts/nuts over torque
42 Missing clips, bands etc

FAILURE CODE 102
A - CODE /3
A CODE
POSITION
43 Improperly tightened clip,
bands etc
40 41 FRAME 44 Fell off, loosened —
42 BODY 45 Interfered
45A Intermittent
46 Missing parts
47 Wrong or different parts
48 Improperly installed
49 Improperly adjusted
Improperly welded, coated
sealant, etc
50 Improperly welded
51 Improperly coated sealants
52 Improperly caulking
53 dhesive failure
53A Excessive sealer/adhesive
53B Loss of bonding/broken
stitches
50 51 EXTERIOR Cavity, mixed foreign mater- 86 Battery dead
ial, etc
52 INTERIOR 55 Cavity, pinhole 87 Improperly painted
54 CHASSIS ELECT ICAL 56 Poor machining 88 Coolant shortage
55 HEATER, AIR COND. 56A Faulty casting 89 Abnormal smell
AND VENT.
57 Clogged
57A Fogged
57B Glazed
58 Mix foreign material
59 Freeze, icing
60 Excessive play
Scratch, Peeling, Rust spot,
Perforation etc.
PA Priming coat defect
60 61 AUXILIARY EQUIP- PB Thin paint (under spray) —
MENT
62 SPECIAL PURPOSE PC Seeding
PD Runs
PE Scratch
PF Adhesion of foreign materi-
als
PG Discoloration
PH Fading
PJ Uneven

102 FAILURE CODE
/4 B - CODE
A CODE
POSITION
PK Blister
PL Flat mark
PM Rust spot (exp)
PN Perforation
PO Over spray
PP Rust (Hem/Joint)
PQ Rust contact
PR Color mismatching
PS Orange peel
PT Peeling
PU Polish/buff mark
PX Other paint defects
B - CODE FRM102BCODE002
POSITION B CODE
10 11 ENGINE 00 Cannot drive 73 Fuel or vacuum leak
12 LUBRICATION 01 Engine stalled 73A Poor sealing
13 FUEL 02 No start or hard to start 75 Low hydraulic or air pressure
14 COOLING 03 Poor idling 75A Air in brake/clutch system
15 INTAKE & EXHAUST 04 Poor Acceleration or in- 80 Abnormal sound/noise
sufficient power
16 ENGINE ELECTRICAL04A Poor engine performance 80A Rattling noise
17 ENGINE CONTROL 05 Panting, stumble/hunting 80B Knocking noise
05A Engine hesitation/surging 80C Humming noise
06 Engine knocking 80D Friction noise
07 Run on 80E Gas flow noise/hissing noise
08 Overheat 80F Buzzing noise
09 Overcool 80G Resonance noise
10 Excessive fuel consump- 81 Squeak
tion
11 Excessive oil consumption 82 Vibration
12 Excessive exhaust smoke 82A Shimmy
12A White smoke 84 Excessive stroke or short of
stroke
13 Over charge 85 Excessive pedal effort / Heavy
operation
70 Fuel leak 86 Too weak pedal effort
70A Fuel smell 88 Improper returning
70B Exhaust smoke smell 90 Stain
70C Exhaust gas leaking 91 Out / hard to control
71 Oil or grease leak 92 Fire
71A Lubricant leak 99 Others

FAILURE CODE 102
B - CODE /5
POSITION B CODE
72 Water leak
72A Coolant leak
20 21 CLUTCH 00 Cannot drive 80 Abnormal sound, noise
22 TRANSMISSION (M/T) 01 Engine stalled 80A Rattling noise
23 TRANSMISSION (A/T) 07 Run on 80B Knocking noise
24 PROPELLER SHAFT 20 Clutch slipping 80C Humming noise
26 FRONT AXLE 21 Gear jump out 80D Friction noise
27 REAR AXLE 22 Gear stick in 80E Gas flow noise/hissing noise
23 Cannot shift gear 80F Buzzing noise
23A Difficult engagement 80G Resonance noise
23B Difficult disengagement 81 Squeak
24 Vague response 82 Vibration, judder
25 Improper shifting 82A Shimmy
26 Shock when shifting 84 Excessive stroke or short of
stroke
27 Shaft came off 85 Excessive pedal effort/Heavy
operation
71 Oil or grease leak 86 Too weak pedal effort
71A Lubricant leak 87 Unstable pedal stroke
72 Water leak 87A Excessive play
72A Coolant leak 99 Others
73 Vacuum or air leak
73A Poor sealing
30 31 WHEEL & TYRE 30 Ineffectiveness 80A Rattling noise
32 POWER PLANT MOUNT 30A Poor braking/spongy 80B Knocking noise
33 FRONT SUSPENSION30B Brake dragging/jammed 80C Humming noise
34 REAR SUSPENSION30C Poor visibility glass/mirror 80D Friction noise
35 SERVICE BRAKE 30D Improper retraction 80E Gas flow noise/hissing noise
36 PARKING BRAKE 30E Poor connection 80F Buzzing noise
37 STEERING — — 80G Resonance noise
31A Pulling to the right 81 Squeak
31B Pulling to the left 82 Vibration
35 Improper driving stability 82A Shimmy
36 Drift one side 84 Excessive stroke or short of
stroke
71 Oil or grease leak 85 Excessive pedal effort / heavy
operation
71A Lubricant leak 86 Too weak pedal effort
72 Water leak 87 Unstable pedal stroke
73 Vacuum or air leak 87A Excessive play
73A Poor sealing 88 Improper return
75 Low hydraulic or air 90 Stain
pressure
75A Air in brake/clutch system 99 Others

102 FAILURE CODE
/6 B - CODE
POSITION B CODE
80 Abnormal sound, noise
40 41 FRAME 30 Ineffectiveness 59 Fault operation
42 BODY 30E Poor connection 59A Improper locking/unlocking
36 Drift one side 59B Operation short distance
40 Water penetration 71 Oil or grease leak
40A Water condensation 71A Lubricant leak
41 Dust entering 72 Water leak
42 Cold air leak, enter 73A Poor sealing
43 Wind noise 80 Abnormal sound, noise
44 Body leaning 80A Rattling noise
44A Dented inward 80B Knocking noise
44B Dented outward 80C Humming noise
45 Uncomfortable riding 80D riction noise
46 Improper closing 80E Gas flow noise/hissing noise
46A Improper opening 80F Buzzing noise
47 Improper alignment 80G Resonance noise
47A Vehicle height uneven 82 Vibration, judder
54 Noise 82A Shimmy
55 Distorted sound 84 Excessive stroke or short of
stroke
55A Poor reception/interfer- 85 Excessive pedal effort / heavy
ence operation
56 Poor fit 86 Too weak pedal effort
58 Unattractiveness 88 Improper return
58A Poor appearance 90 Stain
58B Loss of bonding/broken 92 Fire
stitches
99 Others
50 51 EXTERIOR 00 Cannot drive 59A Improper locking/unlocking
52 INTERIOR 01 Engine stalled 59B Operation short distance
54 CHASSIS ELECTRICAL 02 No start or hard to start 72 Water leak
55 HEATER, AIR CONDITION- 30 Ineffectiveness 73 Gas or air leak
ER AND VENTILATION
30C Poor visibility glass/mirror 73A Poor sealing
30D Improper retraction 74 Refrigerant leak
30E Poor connection 80 Abnormal sound, noise
40 Water penetration 80A Rattling noise
40A Water condensation 80B Knocking noise
41 Dust entering 80C Humming noise
46 Improper closing 80D Friction noise
46A Improper opening 80E Gas flow noise/hissing noise
50 Battery dead 80F Buzzing noise
50A No / insufficient generat- 80G Resonance noise
ing/charge

FAILURE CODE 102
B - CODE /7
POSITION B CODE
51 Improper indication 82 Vibration
51A Warning light ON 82A Shimmy
51B Inaccurate instrument 84 Excessive stroke or short of
reading stroke
52 No or poor lighting 85 Excessive pedal effort / heavy
operation
53 Horn does not sound 86 oo weak pedal effort or reac-
tion
54 Noise 88 Improper return
55 Distorted sound 90 Stain
55A Poor reception/interfer- 92 ire
ence
56 Poor fit 99 Others
57 Improper wiping
58 Unattractiveness
58A Poor appearance
58B Loss of bonding/broken
stitches
59 Operation failure faulty
actuation
60 61 AUXILIARY EQUIPMENT 99 Others
62 SPECIAL PU POSE

102 FAILURE CODE
/8 C-CODE
C - CODE FRM102CCODE003
POSITION C CODE
10 11 ENGINE A – When engine starting
12 LUBRICATION B – When warning-up
13 FUEL C – When idling
14 COOLING E – When starting
15 INTAKE & EXHAUST F – When shift changing
16 ENGINE ELECTRICAL G – When accelerating
17 ENGINE CONTROL H – When decelerating
20 21 CLUTCH J – When braking
22 TRANSMISSION (M/T) L – When running at low speed (20km/h or
23 TRANSMISSION (A/T) more)
24 PROPELLAR SHAFT M – When running at high speed (80 km/h
26 FRONT AXLE or more)
27 REAR AXLE P – At cold engine
Q – At hot engine
30 31WHEEL & TYRE
R – When towing
32POWER PLANT MOUN T
S – When being highly loaded
34SERVICE BRAKE
T – When turning
36PARKING BRAKE
U – When backing
37STEERING
V – When racing
40 41 FRAME X – When using PTO
42 BODY Y – When loaded
50 51 EXTE IOR Z – When unloaded
52 INTE IOR 0 – When ascending
54 CHASSIS 1 – When descending
60 61AUXILIARY EQUIPMENT 2 – Bad road condition
62SPECIAL PURPOSE 3 – Muddy road or area
4 – Highland
5 – At low temperature (0 °C (32 °F) or less)
6 – At high temperature (30 °C (86 °F) or
more)
7 – Rainy
8 – Snowy
9 – Windy

WORKSHOP MANUAL ALL
Position Code Index /1
00 GENERAL 1131 INLET VALVE GENERAL

113110 10 INLET VALVE ... REPLACEMENT
11-10
11 ENGINE (ALL)........................................
113113 10 INLET VALVE STEM SEAL ...

1100 ENGINE REPLACEMENT 11-10
..........................
110010 10 ENGINE ASSY ... REPLACEMENT.... 11-10 113114 10 INLET VALVE SPRING ...
110010 20 ENGINE ASSY ... OVERHAUL ........ 11-10 REPLACEMENT (ALL).................. 11-10
110010 40 ENGINE ASSY ... ADJUSTMENT..... 11-10 113150 10 EXHAUST VALVE ... REPLACEMENT
110010 92 IGNITION TIMING-ADJUSTMENT... 11-10 (ALL)........................................ 11-10
110011 10 SHORT ENGINE ASSY ... 113153 10 EXHAUST VALVE STEM SEAL ...
REPLACEMENT.......................... 11-10 REPLACEMENT (ALL).................. 11-10
1111 ENGINE CYLINDER BLOCK GENERAL 113154 10 EXHAUST VALVE SPRING ...
111110 10 CYLINDER BLOCK ASSY ... REPLACEMENT 11-10
..........................
REPLACEMENT.......................... 11-10 1132 ENGINE ROCKER ARM & SHAFT GENERAL

1112 ENGINE CYLINDER HEAD GENERAL 113235 10 APPET LASH ADJUSTER ...
111210 10 CYLINDER HEAD ASSY ... REPLACEMENT (ALL).................. 11-10
REPLACEMENT.......................... 11-10 1133 ENGINE CAMSHA GENERAL
111210 20 CYLINDER HEAD ASSY ... 113310 10 CAMSHAFT ASSY ... REPLACEMENT
OVERHAUL............................... 11-10 (One piece)............................... 11-10
111221 10 CYLINDER HEAD GASKET ... 113340 10 CAMSHAFT OIL SEAL ...
REPLACEMENT.......................... 11-10 REPLACEMENT (One piece)......... 11-10
1113 ENGINE CASE & COVER GENERAL 1134 ENGINE TIMING BELT GENERAL
111310 10 ROCKER COVER SSY ... 113410 10 TIMING BELT (A)...
REPLACEMENT.......................... 11-10 REPLACEMENT 11-10
..........................
111311 10 ROCKER COVER G SKET ... 113430 10 FEAD BELT (AUXILARIES BELT) ...
..........................
111320 10 OIL PAN ASSY ... REPL CEMENT.... 11-10 1135 ENGINE BELT TENSIONER
111321 10 OIL PAN GASKET (LIQUID G SKET) 113510 10 TIMING BELT TENSIONER ASSY ...
... REPLACEMENT....................... 11-10 REPLACEMENT 11-10
..........................
111330 10 FRONT CASE ASSY ... 113530 10 AUTO TENSIONER ...

..........................
111331 10 FRONT CASE GASKET ... 1136 ENGINE SPROCKET GENERAL

REPLACEMENT.......................... 11-10 113610 10 CRANKSHAFT SPROCKET ...
111351 10 TIMING BELT F ONT UPPER COVER REPLACEMENT 11-10
..........................
... REPLACEMENT....................... 11-10 113620 10 CAMSHAFT SPROCKET ...

111352 10 TIMING BELT FRONT LOWER REPLACEMENT (One piece)......... 11-10
COVER ... REPLACEMENT............ 11-10
111365 10 ENGINE COVER ... 12 LUBRICATION
REPLACEMENT.......................... 11-10
111382 10 L A ER FRAME ... 1210 ENGINE OIL PUMP GENERAL
REPLACEMENT.......................... 11-10 121010 10 O I L PUMP ASSY ...
1121 ENGINE PISTON GENERAL REPLACEMENT 12-3 ..........................
112110 10 PISTON ... REPLACEMENT (ALL).... 11-10 121010 20 OIL PUMP ASSY ... OVERHAUL..... 12-3
112120 10 PISTON RING ... REPLACEMENT 121013 10 INNER GEAR ... REPLACEMENT..... 12-3
(ALL)........................................ 11-10 121014 10 OUTER GEAR ... REPLACEMENT.... 12-3
1122 ENGINE CONNECTING ROD GENERAL 121061 10 OIL SCREEN (STRAINER) ...
112210 20 CONNECTING ROD ASSY ... REPLACEMENT 12-3 ..........................
REPLACEMENT (ALL).................. 11-10 1220 ENGINE OIL FILTER & BRACKET GENERAL
112220 10 CONNECTING ROD BEARING (BIG 122020 10 O I L FILTER ASSY...
END) ... REPLACEMENT (ALL)....... 11-10 REPLACEMENT 12-3 ..........................
1123 ENGINE CRANKSHAFT GENERAL 1230 ENGINE OIL COOLER GENERAL

112310 10 CRANKSHAFT ASSY ... 123010 10 O I L COOLER ASSY...
REPLACEMENT.......................... 11-10 REPLACEMENT 12-3 ..........................
112320 10 CRANKSHAFT MAIN-BEARING ... 125012 10 OIL FILLER CAP ... REPLACEMENT.. 12-3
REPLACEMENT (ALL).................. 11-10 1282 SWITCH GENERAL
112342 10 CRANKSHAFT OIL SEAL (FRONT) ... 128201 10 OIL PRESSURE SWITCH ...
112352 10 CRANKSHAFT OIL SEAL (REAR) ... 128201 84 OIL PRESSURE SWITCH ...
112370 10 CRANKSHAFT PULLEY ... 1286 SOLENOID VALVE GENERAL

REPLACEMENT.......................... 11-10 128601 10 CPS SOLENOID VALVE ...
1124 ENGINE FLYWHEEL GENERAL REPLACEMENT 12-3 ..........................
112410 10 FLYWHEEL ... REPLACEMENT....... 11-10

112411 10 FLYWHEEL RING GEAR ... 13 FUEL
REPLACEMENT.......................... 11-10
112420 10 DRIVE PLATE ... REPLACEMENT.... 11-10 1331 ECI-MULTI GENERAL

ALL WORKSHOP MANUAL
/2 Position Code Index
133110 10 INJECTOR (ECI-MULTI) ... 1422 ENGINE WATER PIPE & HOSE GENERAL
REPLACEMENT.......................... 13-7 142221 10 BY PASS HOSE / WATER RETURN
133111 10 INSULATOR (ECI-MULTI) ... HOSE ... REPLACEMENT.............. 14-6
REPLACEMENT (AII).................... 13-7 142225 10 WATER THERMOSTAT PIPE ...
133121 10 THROTTLE BODY (ECI-MULTI) ... REPLACEMENT.......................... 14-6
REPLACEMENT.......................... 13-7 142233 10 WATER THERMOSTAT HOSE ...
133131 10 INJECTION PRESSURE REGULATOR REPLACEMENT.......................... 14-6
(ECI-MULTI) ... REPLACEMENT...... 13-7 142234 10 WATER RETURN ...
133132 10 DELIVERY PIPE (ECI-MULTI) ... REPLACEMENT.......................... 14-6
REPLACEMENT.......................... 13-7 142235 10 WATER FEED HOSE ...
1350 FUEL PUMP GENERAL REPLACEMENT.......................... 14-6
135020 10 FUEL PUMP ASSY (ELECTRICAL) ... 1440 COOLING FAN & COUPLING GENERAL
REPLACEMENT.......................... 13-7 144030 10 COOLING FAN ASSY (ELECTRIC) ...
1360 FUEL TANK GENERAL REPLACEMENT.......................... 14-6
136010 10 FUEL TANK ASSY... 144031 10 COOLING FAN (ELECTRIC) ...
REPLACEMENT.......................... 13-7 REPLACEMENT.......................... 14-6
136021 10 FUEL TANK FILLER NECK HOSE ... 1450 RADIA OR & RESERVOIR (SURGE) ANK GENERAL
REPLACEMENT.......................... 13-7 145010 10 RADIATOR ASSY ...
136022 10 FUEL TANK BREATHER HOSE ... REPLACEMENT.......................... 14-6
REPLACEMENT.......................... 13-7 145034 10 RADIATOR SHROUD ...
136032 10 FUEL TANK VAPOR HOSE ... REPLACEMENT.......................... 14-6
REPLACEMENT.......................... 13-7 145050 10 RESERVOIR (CONDENSE) TANK
1370 FUEL LINE GENERAL ASSY ... REPLACEMENT............... 14-6
137010 10 FUEL FILTER SSY ... 1460 R DIATOR WATER LINE GENERAL
REPLACEMENT.......................... 13-7 146021 10 RADIATOR HOSE (UPPER) ...
137031 10 FUEL HOSE (ENGINE) ... REPLACEMENT (One piece) ......... 14-6
REPLACEMENT.......................... 13-7 146022 10 RADIATOR HOSE (LOWER) ...
137051 10 FUEL HOSE (FUEL T NK) ... REPLACEMENT (One piece) ......... 14-6
REPLACEMENT.......................... 13-7 146023 10 RUBBER HOSE (RADIATOR TO
137053 10 FUEL HOSE ETU N (FUEL TANK) TANK) ... REPLACEMENT (One
... REPLACEMENT....................... 13-7 piece)....................................... 14-6
137073 10 FUEL ETU N PIPE ... 1481 MOTOR AND ACTUATOR GENERAL
REPLACEMENT.......................... 13-7 148101 10 RADIATOR FAN MOTOR ...
137075 10 FUEL VAPO PIPE ... REPLACEMENT.......................... 14-6
REPLACEMENT.......................... 13-7 1482 SWITCH GENERAL
137086 10 FUELCUT-OFFVALVE... 148201 10 RADIATOR FAN MOTOR THERMO
REPLACEMENT.......................... 13-7 SWITCH (SENSOR) ...
1383 SENSOR AND GAUGE UNIT GENERAL REPLACEMENT.......................... 14-6
138311 10 WATER TEMPERATURE SENSOR 1483 SENSOR AND GAUGE UNIT GENERAL
(ECI-MULTI) ... REPLACEMENT...... 13-7 148301 10 WATER TEMPERATURE GAUGE
138313 10 THROTTLE POSITION SENSOR UNIT ... REPLACEMENT............... 14-6
(ECI-MULTI) ... REPLACEMENT...... 13-7 1484 RELAY AND FLASHER UNIT GENERAL
138320 10 ACCELERATING POSITION SENSOR 148401 10 RADIATOR FAN MOTOR RELAY ...
... REPLACEMENT....................... 13-7 REPLACEMENT.......................... 14-6
138323 10 TEMPERATURE PRESSURE SENSOR
/ MAP SENSOR ... REPLACEMENT... 13-7 15 INTAKE AND EXHAUST
138351 10 OXYGEN SENSOR (BEFORE FCC) ...
REPLACEMENT.......................... 13-7 1511 INTAKE MANIFOLD GENERAL
1384 RELAY AND FLASHER UNIT GENERAL 151110 10 INTAKE MANIFOLD ASSY ...
138401 10 MPI CONTROL RELAY ... REPLACEMENT.......................... 15-5
REPLACEMENT.......................... 13-7 151111 10 INTAKE MANIFOLD O-RING ...
1385 CONTROL UNIT GENERAL REPLACEMENT (ALL).................. 15-5
138501 10 MPI CONTROL UNIT ... 151143 10 VARIABLE AIR VACCUM TANK ...
1512 AIR CLEANER GENERAL
14 COOLING 151210 10 AIR CLEANER ASSY ...
REPLACEMENT 15-5
1410 WATER PUMP GENERAL 151211 10 AIR CLEANER ELEMENT ...
141010 10 WATER PUMP ASSY ... REPLACEMENT.......................... 15-5
REPLACEMENT.......................... 14-6 151250 10 RESONATOR ... REPLACEMENT..... 15-5
141012 10 WATER PUMP SEAL ... 1531 EXHAUST MANIFOLD GENERAL
14-6
REPLACEMENT.......................... 153110 10 EXHAUST MANIFOLD ASSY ...
141025 10 WATER PUMP RECIRCULATION REPLACEMENT.......................... 15-5
ASSY ... REPLACEMENT............... 14-6 153120 10 EXHAUST MANIFOLD GASKET ...
1421 THERMOSTAT GENERAL REPLACEMENT.......................... 15-5
142110 10 THERMOSTAT ... REPLACEMENT.... 14-6

WORKSHOP MANUAL ALL
153122 10 EXHAUST MANIFOLD COVER ... 1683 SENSOR AND GAUGE UNIT GENERAL
REPLACEMENT.......................... 15-5 168301 10 KNOCK SENSOR ...
1532 FRONT EXHAUST PIPE GENERAL REPLACEMENT.......................... 16-5
153210 10 FRONT EXHAUST PIPE ASSY ... 168321 10 CRANKSHAFT ANGLE SENSOR ...
153211 10 FRONT EXHAUST PIPE GASKET ... 168322 10 CAMSHAFT ANGLE SENSOR ...
1535 MAIN MUFFLER GENERAL 1684 RELAY AND FLASHER UNIT GENERAL
153510 10 MAIN MUFFLER ASSY ... 168401 10 STARTER RELAY ...
1537 CATALYTIC CONVERTER GENERAL 168441 10 AL ERNA OR RELAY ...
153710 10 CATALYTIC CONVERTER ASSY REPLACEMENT.......................... 16-5
(FRONT) ... REPLACEMENT ........... 15-5
1581 MOTOR AND ACTUATOR GENERAL 17 EMISSION CON ROL
158112 10 VIM MOTOR (INTAKE MANIFOLD)
... REPLACEMENT....................... 15-5 1711 ACCELERA OR GENERAL
158113 10 VIM ACTUATOR (INTAKE 171111 10 ACCELERA OR PEDAL ...
MANIFOLD) ... REPLACEMENT...... 15-5 REPLACEMENT.......................... 17-4
1583 SENSOR AND GAUGE UNIT GENERAL 1731 VAPOR PREVENTIVE DEVICE GENERAL
158303 10 MOTOR SENSOR ... 173110 10 CANISTER ASSY ...
1736 BLOW-BY GAS REDUCING DEVICE GENERAL
173630 10 BREATHER HOSE ... REPLACEMENT
16 ENGINE ELECTRICAL (One piece)............................... 17-4
1611 ALTERNATOR GENERAL 1782 SWITCH GENERAL
161110 10 ALTERNATOR SSY ... 178201 10 ACCELERATOR PEDAL SWITCH
REPLACEMENT .......................... 16-5 (AUTO CRUISE) ... REPLACEMENT.. 17-4
161110 20 ALTERNATOR SSY ... 178203 10 AUTO CRUISE SWITCH ...
OVE HAUL............................... 16-5 REPLACEMENT.......................... 17-4
161121 10 ALTE NATOR IC EGULATOR ... 178204 10 AUTO CRUISE MAIN SWITCH ...
REPLACEMENT .......................... 16-5 REPLACEMENT.......................... 17-4
161122 10 ALTE NATOR B USH HOLDER ASSY 1783 SENSOR AND GAUGE UNIT GENERAL
... REPLACEMENT....................... 16-5 178315 10 ACCELERATOR PEDAL SENSOR ...
161125 10 ALTE NATOR ECTIFIER ... REPLACEMENT.......................... 17-4
REPLACEMENT .......................... 16-5 1785 CONTROL UNIT GENERAL
161126 10 ALTERNATOR STATOR ASSY... 178501 10 AUTO CRUISE ( AUTO SPEED)
REPLACEMENT .......................... 16-5 CONTROL UNIT ...
161127 10 ALTERNATOR ROTOR ASSY ... REPLACEMENT.......................... 17-4
REPLACEMENT .......................... 16-5 1786 SOLENOID VALVE GENERAL
1621 STARTER GENERAL 178635 10 PURGE CONTROL VALVE ...
162110 10 STARTER ASSY ... REPLACEMENT... 16-5 REPLACEMENT 17-4
.........................
162110 20 STARTER ASSY ... OVERHAUL ....... 16-5 178661 10 CANISTER BLEED SOLENOID VALVE
162112 10 STARTER SWITCH ASSY ... ... REPLACEMENT....................... 17-4
REPLACEMENT .......................... 16-5
162113 10 STARTER ARMATURE ASSY ... 21 CLUTCH
REPLACEMENT .......................... 16-5
162122 10 STARTER BRUSH ... 2111 CLUTCH DISC & COVER ASSY GENERAL
REPLACEMENT .......................... 16-5 211110 10 CLUTCH DISC ... REPLACEMENT.... 21-3
162124 10 STARTER OVERRUNNING CLUTCH 211120 10 CLUTCH COVER ASSY ...
... REPLACEMENT....................... 16-5 REPLACEMENT.......................... 21-3
162126 10 STARTER GEAR ASSY ... 2120 CLUTCH CONTROL GENERAL
REPLACEMENT .......................... 16-5 212011 10 CLUTCH PEDAL ...
162128 10 STARTER LEVER SET ASSY ... REPLACEMENT.......................... 21-3
REPLACEMENT .......................... 16-5 212011 40 CLUTCH PEDAL ... ADJUSTMENT... 21-3
1631 IGNITION COIL GENERAL 212014 10 CLUTCH PEDAL BUSHING ...
163110 10 IGNITION COIL ASSY ... REPLACEMENT.......................... 21-3
REPLACEMENT (All).................... 16-5 212030 10 CLUTCH MASTER CYLINDER ASSY
1634 CABLE GENERAL ... REPLACEMENT....................... 21-3
163410 10 HIGH TENSION CABLE ASSY ... 212030 20 CLUTCH MASTER CYLINDER ASSY
REPLACEMENT (All).................... 16-5 ... OVERHAUL............................ 21-3
1634 CABLE GENERAL 212050 10 CLUTCH RELEASE CYLINDER ASSY
163410 10 HIGH TENSION CABLE ASSY ... ... REPLACEMENT....................... 21-3
REPLACEMENT (ALL).................. 16-5 212050 20 CLUTCH RELEASE CYLINDER ASSY
1635 SPARK PLUG GENERAL ... OVERHAUL............................ 21-3
163510 10 SPARK PLUG ASSY ... 212071 10 CLUTCH RELEASE BEARING ...
REPLACEMENT (ALL).................. 16-5 REPLACEMENT.......................... 21-3

ALL WORKSHOP MANUAL
/ 4. Position Code Index
212074 10 CLUTCH RELEASE FORK ... 2331 TRANSMISSION CASE & HOUSING GENERAL
REPLACEMENT.......................... 21-3 233113 80 T/M DRIVE SHAFT OIL SEAL ...
212081 10 CLUTCH HOSE ... REPLACEMENT REPLACEMENT (LEFT)................. 23-7
(One piece)............................... 21-3 233113 82 T/M DRIVE SHAFT OIL SEAL ...
REPLACEMENT (RIGHT)............... 23-7
233141 10 T/M OIL PAN ... REPLACEMENT..... 23-7
233142 10 T/M OIL PAN GASKET ...
2211 TRANSMISSION CONTROL GENERAL REPLACEMENT .......................... 23-7
221111 10 T / M SHIFT LEVER ... 2351 TRANSFER CASE & CHAIN COVER (REAR CASE) GENERAL
REPLACEMENT.......................... 22-7 235112 10 T/F CASE INPUT SHAFT OIL SEAL ...
221112 10 T/M SHIFT LEVER KNOB ... REPLACEMENT .......................... 23-7
REPLACEMENT.......................... 22-7 2375 TRANSMISSION OIL LUBRICA ION GENERAL
221115 10 T/M SHIFT LEVER BOOT (COVER) ... 237510 10 /M OIL HOSE ... REPLACEMENT.... 23-7
REPLACEMENT.......................... 22-7 237530 10 / M OIL COOLER...
221171 10 T/M CONTROL CABLE ... REPLACEMENT .......................... 23-7
REPLACEMENT.......................... 22-7 2383 SENSOR AND GAUGE UNIT GENERAL
2220 TRANSMISSION UNIT GENERAL 238311 10 INPUT SPEED SENSOR ...
222010 10 T/M ASSY ... REPLACEMENT......... 22-7 REPLACEMENT .......................... 23-7
222010 20 T/M ASSY ... OVERHAUL.............. 22-7 238312 10 OUTPUT SPEED SENSOR ...
222010 9A T/M GROUP WORK (A)................ 22-7 REPLACEMENT .......................... 23-7
222010 9B T/M GROUP WORK (B)................ 22-7 2385 CONTROL UNIT GENERAL
222010 9C T/M GROUP WORK (C)................ 22-7 238501 10 T/M ELC CONTROL UNIT ...
222010 9D T/M GROUP WORK (D)................ 22-7 REPLACEMENT .......................... 23-7
222010 9E T/M GROUP WORK (E)................ 22-7 2389 ELECTRICAL EQUIPMENT GENERAL (OTHERS)
222010 9F T/M GROUP WORK (F)................ 22-7 238901 10 GEAR SHIFT LEVER INDICATOR LED
222010 9G T/M GROUP WORK (G)................ 22-7 BULB ... REPLACEMENT............... 23-7
222010 9H T/M GROUP WORK (H)................ 22-7
222010 9J T/M GROUP WORK (J)................. 22-7
2221 TRANSMISSION CASE & HOUSING GENE L
26 FRONT XLE
222113 80 T/M D IVE SHAFT OIL 2661 FRONT AXLE HOUSING ASSY (EXCEPT DIFFERENTIAL)
SEAL-REPLACEMENT (LEFT)......... 22-7 266121 10 FRONT DRIVE KNUCKLE ...
222113 82 T/M D IVE SHAFT OIL REPLACEMENT (One side)........... 26-3
SEAL-REPLACEMENT ( IGHT)....... 22-7 266124 94 KNUCKLE OIL SEAL (INNER) ...
2222 TRANSMISSION GEAR SHIFTER GENE AL REPLACEMENT (One side)........... 26-3
222260 90 POPPET BALL, SP ING, PLUG ... 266124 96 KNUCKLE OIL SEAL (OUTER) ...
REPLACEMENT.......................... 22-7 REPLACEMENT (One side)........... 26-3
2240 TRANSMISSION ATTACHING EQUIPMENT GENERAL 266141 10 FRONT WHEEL HUB ...
224011 10 SPEE OMETER RIVEN GEAR REPLACEMENT (One side)........... 26-3
SLEEVE ... REPLACEMENT............ 22-7 266142 10 FRONT WHEEL HUB BOLT ...
224013 10 SPEE OMETER RIVEN GEAR ... REPLACEMENT (One side)........... 26-3
REPLACEMENT.......................... 22-7 266148 10 WHEEL HUB BEARING (DOUBLE
224021 10 SPEE OMETER CABLE ... ROW ANGULAR CONTACT TYPE)
REPLACEMENT.......................... 22-7 ... REPLACEMENT (One side)........ 26-3
2282 SWITCH GENERAL 266180 80 FRONT DRIVE SHAFT ASSY (LH) ...
228201 10 BACK-UP SWITCH ... REPLACEMENT.......................... 26-3
REPLACEMENT.......................... 22-7 266180 81 FRONT DRIVE SHAFT ASSY (LH) ...
OVERHAUL............................... 26-3
266180 82 FRONT DRIVE SHAFT ASSY (RH) ...
REPLACEMENT.......................... 26-3
2311 TRANSMISSION CONTROL GENERAL 266180 83 FRONT DRIVE SHAFT ASSY (RH) ...
231110 10 T/M SELECTOR LEVER ASSY ... OVERHAUL............................... 26-3
REPLACEMENT.......................... 23-7 266183 80 DRIVE SHAFT BOOT (LH) ...
231112 10 T/M SELECTOR HANDLE ... REPLACEMENT.......................... 26-3
REPLACEMENT.......................... 23-7 266183 82 DRIVE SHAFT BOOT (T.J SIDE) ...
231118 10 T/M INDICATOR PANEL ... REPLACEMENT.......................... 26-3
REPLACEMENT.......................... 23-7
231131 10 T/M CONTROL (SELECT) CABLE ...
REPLACEMENT.......................... 23-7
27 REAR AXLE
2330 TRANSMISSION UNIT GENERAL 2711 REAR AXLE SHAFT GENERAL
233010 10 T/M ASSY ... REPLACEMENT......... 23-7 271141 10 REAR WHEEL HUB ...
233010 20 T/M ASSY ... OVERHAUL.............. 23-7 REPLACEMENT (One side)........... 27-3
233010 9A T/M GROUP WORK (A)................ 23-7 271142 10 REAR WHEEL HUB BOLT ...
233010 9B T/M GROUP WORK (B)................ 23-7 REPLACEMENT (One side)........... 27-3
233010 9C T/M GROUP WORK (C)................ 23-7 271144 10 REAR WHEEL HUB BEARING
233010 9D T/M GROUP WORK (D)................ 23-7 (INNER) ... REPLACEMENT (One
233010 9E T/M GROUP WORK (E)................ 23-7 side)........................................ 27-3

WORKSHOP MANUAL ALL
31 WHEEL AND TYRE 346213 10 REAR STRUT INSULATOR ASSY ...

REPLACEMENT (One side)........... 34-3
3110 WHEEL & TYRE GENERAL
3463 REAR SHOCK ABSORBER GENERAL (TRAILING ARM)
311010 10 WHEEL ASSY ... REPLACEMENT
346310 10 REAR SHOCK ABSORBER ASSY ...
(One piece)............................... 31-3
311015 10 DISC WHEEL ... REPLACEMENT (One
346311 10 REAR SHOCK ABSORBER ...
piece)....................................... 31-3
3120 WHEEL CAP GENERAL
312012 10 CENTER CAP ... REPLACEMENT (One
piece)....................................... 31-3 35 SERVICE BRAKE
3140 SPARE TYRE GENERAL 3500 SERVICE BRAKE
314021 10 SPARE TYRE CARRIER (HANGER) ... 350000 94 BRAKE SYS EM ... BLEED............ 35-7
REPLACEMENT ......................... 31-3 3511 BRAKE MAS ER CYLINDER GENERAL
351110 10 BRAKE MAS ER CYLINDER ASSY ...
32 POWER PLANT MOUNT REPLACEMENT.......................... 35-7
351110 20 BRAKE MAS ER CYLINDER ASSY ...
3211 ENGINE & TRANSMISSION MOUNTING MEMBER
OVERHAUL............................... 35-7
GENERAL 3512 BRAKE BOOSTER GENERAL
321113 10 SUB FRAME MODULE ASSY ... 351210 10 BRAKE BOOSTER ASSY ...
REPLACEMENT.......................... 32-3 35-7
REPLACEMENT..........................
3212 ENGINE SUPPORT GENERAL 351212 10 BRAKE BOOSTER CHECK VALVE ...
321221 10 ENGINE FRONT ROLL STOPPER ... 35-7
REPLACEMENT..........................
REPLACEMENT.......................... 32-3 3522 FRONT DISC BRAKE GENERAL
321222 10 ENGINE MOUNTING ... 352211 10 FRONT BRAKE DISC (ROTOR) ...
REPLACEMENT.......................... 32-3 REPLACEMENT (One side)........... 35-7
321223 10 T / M MOUNTING ... 352211 89 FRONT BRAKE DISC (BOTH SIDE) ...
REPLACEMENT.......................... 32-3 ON VEHICLE GRINDING ............... 35-7
321224 10 REAR ROLL STOPPER (INSULATOR) 352220 10 DISC BRAKE CALIPER ASSY ...
... REPLACEMENT....................... 32-3 REPLACEMENT (One side)........... 35-7
352220 20 DISC BRAKE CALIPER ASSY ...
33 FR

Preve Suprima Workshop Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Preve Suprima Workshop Manual

Uploaded by

Copyright:

Available Formats

WORKSHOP MANUAL

INSPECTION & MAINTENANCE

Printed in Malaysia 13 February 2012 Eng

00 GENERAL ................................................................................... 00/1 - 00/10

Printed in Malaysia 13 February 2012 Eng

Printed in Malaysia 13 February 2012 Eng

HOW TO USE THIS MANUAL ....................................................... 00/3

PRECAUTIONS BEFORE SERVICE ................................................... 00/4

SUPPORT LOCATIONS FOR LIFTING AND JACKING ............................. 00/8

Printed in Malaysia 13 February 2012 Eng

Printed in Malaysia 13 February 2012 Eng

HOW TO USE THIS MANUAL PDI000GINFO11001

EXPLANATION OF MANUAL CONTENTS

Printed in Malaysia 13 February 2012 Eng

P.A.D.T : Proton Advance Diagnostic Tool

PRECAUTIONS BEFORE SERVICE

PROTECTING THE VEHICLE

DOING SERVICE WORK IN GROUPS OF

Printed in Malaysia 13 February 2012 Eng

REMOVAL AND DISASSEMBLY

If punch marks or marks or mating marks are

Printed in Malaysia 13 February 2012 Eng

TUBES AND OTHER RUBBER PARTS

because if it adheres to any tubes or rubber parts,

Printed in Malaysia 13 February 2012 Eng

SERVICING THE ELECTRICAL SYSTEM

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Printed in Malaysia 13 February 2012 Eng

SUPPORT LOCATIONS FOR LIFTING AND JACKING PDI000SLIFT11001

DOIIP000R9005 DOIIP000R9006 DOIIP000R9007

Printed in Malaysia 13 February 2012 Eng

2. Place the attachments (G) on the H-bar lift

Printed in Malaysia 13 February 2012 Eng

MAKING WOODEN ATTACHMENTS

Item Size Quantity

between; make four attachments such as

Printed in Malaysia 13 February 2012 Eng

TABLE OF PRE-DELIVERY INSPECTION ............................................ 1/4

PAINTWORK TERMS .................................................................. 1/6

FIRST STEP .............................................................................. 1/7

BODY .................................................................................... 1/7

UNDER HOOD ......................................................................... 1/11

10. POWER STEERING FLUID LEVEL ............................................. 1/12

UNDER VEHICLE ....................................................................... 1/13

BEFORE ROAD TEST .................................................................. 1/15

ROAD TEST ............................................................................. 1/18

Printed in Malaysia 13 February 2012 Eng

24. ENGINE PERFORMANCE AND EXHAUST GAS ............................. 1/18

AFTER ROAD TEST .................................................................... 1/20

FINAL STEP ............................................................................. 1/22

Printed in Malaysia 13 February 2012 Eng

Printed in Malaysia 13 February 2012 Eng

NOTES CONCERNING ENTRIES

This section describes the details and the inspec-

TABLE OF PRE-DELIVERY INSPECTION PDI001TABLE11001

Printed in Malaysia 13 February 2012 Eng

16. [..........] Seat adjusters and seat back latches

Printed in Malaysia 13 February 2012 Eng

PAINTWORK TERMS PDI001PAINT11001

Term Definition Remarks

through paint coating.

Printed in Malaysia 13 February 2012 Eng

Term Definition Remarks

FIRST STEP PDI001FIRST11001