MPX English Final Version VOLUME 3

Edition: September 2010 VOLUME 1
Printing: October 2010 INTRODUCTION 01

Pulication NO: FXSM-201009 PREPARATION 02
Printed in China SERVICE SPECIFICATIONS 03
DIAGNOSTICS 04
VOLUME 2
ENGINE CONTROL SYSTEM 11A
FUEL 12A
EMISSION CONTROL 13A
INTAKE AIR 14A
ENGINE MECHANICAL 15A
EXHAUST 16A
COOLING 17A
LUBRICATION 18A
IGNITION 19A
STARTING AND CHARGING 20A
ENGINE CONTROL SYSTEM 11B
FUEL 12B
EMISSION CONTROL 13B
INTAKE AIR 14B
ENGINE MECHANICAL 15B
EXHAUST 16B
COOLING 17B
LUBRICATION 18B
STARTING AND CHARGING 20B
FRONT SUSPENSION 31
REAR SUSPENSION 32
TIRE AND WHEEL 33
AXLE AND PROPELLER SHAFT 34
BRAKE 35
PARKING BRAKE 36
TRANSMISSION 41
VOLUME 3
CLUTCH 42
STEERING COLUMN 51
POWER STEERING 52
HEATER AND AIR CONDITIONING 61
SUPPLEMENTAL RESTRAINT SYSTEM 62
SEAT BELT 63
LIGHTING 64
WIPER AND WASHER 65
AUDIO SYSTEM 66
WIRING 71
COMMUNICATION SYSTEM 81
WINDSHIELD 82
© 2010 Beiqi Foton Motor Co., Ltd INSTRUMENT PANEL 83
SEAT 84
All right reserved. No part of this service DOOR LOCKS 85
manual may be reproduced or stored in a
SLIDING ROOF 86
retrieval system, or transmitted in any form, or
by any means, electronic, mechanical, photo- ENGINE HOOD AND DOORS 87
copying, recording or otherwise, without the EXTERIOR AND INTERIOR TRIM 88
proir written permission of Foton. VEHICLE CONTROL SYSTEM 91
INDEX
CLUTCH
42
CLUTCH SYSTEM ............................................................................. 42-1
PRECAUTION.............................................................................. 42-1
PROBLEM SYMPTOMS TABLE.................................................. 42-2
CLUTCH FLUID.................................................................................. 42-3 42
BLEEDING ................................................................................... 42-3
CLUTCH PEDAL ................................................................................ 42-4
COMPONENTS ........................................................................... 42-4
ADJUSTMENT ............................................................................. 42-5 42
REPLACEMENT .......................................................................... 42-6
CLUTCH MASTER CYLINDER ASSY............................................. 42-10
COMPONENTS ......................................................................... 42-10
REPLACEMENT ........................................................................ 42-11
CLUTCH SLAVE CYLINDER ASSY ................................................ 42-15
COMPONENTS ......................................................................... 42-15
OVERHAUL ............................................................................... 42-16
CLUTCH SUB - ASSY...................................................................... 42-18
COMPONENTS ......................................................................... 42-18 42
OVERHAUL ............................................................................... 42-19
CLUTCH - CLUTCH SYSTEM 42-1
CLUTCH SYSTEM
CLUTCH
PRECAUTION
1. CLUTCH SYSTEM PRECAUTION. 42
(a) In order to prevent clutch stive, be careful not to clean the part by sanding, dry brush or compressed air.
it should be cleaned by water - dipped towel.
42
42-2 CLUTCH - CLUTCH SYSTEM
PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts
Symptom Suspect Area Reference
1. Clutch pedal free play (Undersize) Chapter 42 clutch - clutch pedal, adjustment
2. Clutch disk (Worn) Chapter 42 clutch - clutch subassy, overhaul
Clutch slips 3. Flywheel (Warping) Chapter 42 clutch - clutch subassy, overhaul
4. Clutch cover (Warping) Chapter 42 clutch - clutch subassy, overhaul
5. Diaphragm spring (Failure) Chapter 42 clutch - clutch subassy, overhaul
1. Clutch pedal free play (Oversize) Chapter 42 clutch - clutch pedal, adjustment
2. Diaphragm spring (Failure) Chapter 42 clutch - clutch subassy, overhaul
Chapter 42 clutch - clutch master cylinder assy,

3. Clutch master cylinder (Leakage) replacement
Chapter 42 clutch - clutch slave cylinder assy,

4. Clutch slave cylinder (Leakage) replacement
Clutch does not
disengage 5. Clutch line (Air in line) Chapter 42 clutch - clutch fluid, bleeding
7. Clutch cover (Warping) Chapter 42 clutch - clutch subassy, overhaul
8. Clutch release bearing (Worn) Chapter 42 clutch - clutch subassy, overhaul
9. Clutch release fork (Worn) Chapter 42 clutch - clutch subassy, overhaul
1. Torsion spring (Fracture) Chapter 42 clutch - clutch subassy, overhaul

Clutch noisy
3. Clutch release bearing (Loose) Chapter 42 clutch - clutch subassy, overhaul
4. Clutch pedal (Warping) Chapter 42 clutch - clutch pedal, replacement
1. Clutch disk (Worn or Warping) Chapter 42 clutch - clutch subassy, overhaul
2. Flywheel (Worn) Chapter 42 clutch - clutch subassy, overhaul
3. Clutch cover (Worn) Chapter 42 clutch - clutch subassy, overhaul

Clutch chatters
4. Torsion spring (Fracture or
Chapter 42 clutch - clutch subassy, overhaul
warping)
5. Diaphragm spring (Warping) Chapter 42 clutch - clutch subassy, overhaul
6. Engine mount (Loose) -

CLUTCH - CLUTCH FLUID 42-3
CLUTCH FLUID
BLEEDING
42
1. FILL THE FLUID RESERVOIR WITH CLUTCH FLUID.
Clutch fluid: DOT3
NOTE
Be careful not to splash the clutch fluid to person and
painted surface or it must be washed off immediately.
2. BLEED CLUTCH SLAVE CYLINDER ASSY.

(a) Connect the hose to the bleeding plug.
(b) Depress the clutch pedal several times, then loosen the
bleeding plug with the pedal held down.
(c) At the moment when clutch fluid stops coming out,
tighten the bleeding plug, then release the clutch pedal. 42
(d) Repeat step (b) and (c) until all the air in the fluid has
been bled out.
3. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR.

(a) Check the fluid level and fill the fluid reservoir with clutch
fluid if necessary.
Clutch fluid: DOT 3
42-4 CLUTCH - CLUTCH PEDAL
CLUTCH PEDAL
COMPONENTS
1 Return spring 5 Nut
2 Clutch Pedal Pin 6 Cotter Pin
3 Bolt 7 Clutch Master Cylinder Push Rod Pin
4 Clutch Pedal Support 8 Clutch Pedal

CLUTCH - CLUTCH PEDAL 42-5
ADJUSTMENT
1. INSPECT CLUTCH PEDAL HEIGHT.
(a) Inspect the height between clutch pedal and floor.
42
Specification: 145 ~ 155 mm
2. ADJUST CLUTCH PEDAL HEIGHT.
(a) Loosen the lock nut and turn the stop bolt until the height
is correct. Tighten the lock nut.
Torque: 15 ~ 26 N•m
42
3. INSPECT CLUTCH PEDAL FREE PLAY AND PUSH

ROD PLAY.
(a) Depress the clutch pedal until the pedal resistance begin
to be felt. Inspect the clutch pedal free play L1.
Specification: 10 ~ 15 mm
(b) Gently depress the pedal until the pedal resistance
begins to increase a little.Inspect push rod play L2.
4. ADJUST CLUTCH PEDAL FREE PLAY AND PUSH
ROD PLAY.
(a) Loosen the lock nut and turn the push rod until the clutch
pedal free play and push rod play are correct.
(b) After adjusting the pedal free play, inspect the clutch
pedal height.
REPLACEMENT
1. REMOVE ECM COVER.
(a) Loosen the bolt and removeECM cover.
2. REMOVE CLUTCH PEDAL RETURN SPRING.

(a) Remove the clutch pedal return spring and bushing.
WARNING
Clutch pedal return spring has a heavy spring force, be
careful not to be hurt when removing it.
3. REMOVE CLUTCH MASTER CYLINDER PUSH ROD

PIN.
(a) Remove the cotter pin of the push rod.
(b) Remove the clutch master cylinder push rod and

bushing.
42
4. LOOSEN NUT AND REMOVE CLUTCH PEDAL PIN

AND BUSHING.
42
5. REMOVE CLUTCH PEDAL.

6. INSTALL CLUTCH PEDAL PIN AND BUSHING AND

TIGHTEN NUT.
NOTE
Apply grease to the bushing before installing it.
Grease: Mitsubishi genuine grease Part NO:0101011
or equivalent.
7. INSTALL CLUTCH MASTER CYLINDER PUSH ROD

PIN.
(a) Install the clutch master cylinder push rod and bushing.
NOTE
Grease: Mitsubishi genuine grease. Part NO:0101011
or equivalent.
(b) Install the cotter pin of the push rod.

8. INSTALL CLUTCH PEDAL RETURN SPRING.

(a) Install the clutch pedal return spring and bushing.
WARNING
Clutch pedal return spring has a heavy spring force, be
42
careful not to be hurt when installing it.
NOTE
Grease: Mitsubishi genuine grease. Part NO:0101011
or equivalent.
9. INSTALL ECM COVER.

(a) Install the ECM cover and tighten the bolt.
42
10. INSPECT AND ADJUST THE CLUTCH PEDAL HEIGHT. (Refer to “Chapter 42 clutch - clutch
pedal, adjustment”)
11. INSPECT AND ADJUST THE CLUTCH PEDAL FREE PLAY AND PUSH ROD PLAY. (Refer to
“Chapter 42 clutch - clutch pedal, adjustment”)
42-10 CLUTCH - CLUTCH MASTER CYLINDER ASSY
CLUTCH MASTER CYLINDER ASSY

COMPONENTS
1 Clutch Master Cylinder Housing 7 Dust Boot
2 Spring 8 Clutch Master Cylinder Push Rod Pin
3 Piston 9 Push Rod Clevis
4 Washer 10 Cotter Pin
5 Snap Ring 11 Lock Nut
6 Push Rod 12 Nut

CLUTCH - CLUTCH MASTER CYLINDER ASSY 42-11
REPLACEMENT
1. DRAIN CLUTCH FLUID COMPLETELY.
NOTE 42
Be careful not to splash the brake fluid to person and painted surface or it must be washed off
immediately.
2. REMOVE CLUTCH MASTER CYLINDER ASSY.

(a) Remove the clamp, then disconnect the hose of brake
fluid reservoir.
NOTE
Be careful not to splash the brake fluid to person and
painted surface or it must be washed off immediately.
42
(b) Loosen the nut and disconnect the clutch master cylinder
tube from clutch master cylinder.
(c) Loosen the clutch master cylinder assy nut positioned in

the engine room.
(d) Loosen the clutch master cylinder assy nut positioned in

the driving cab.
(e) Remove clutch master cylinder assy.

CLUTCH - CLUTCH MASTER CYLINDER ASSY 42-13
3. INSTALL CLUTCH MASTER CYLINDER ASSY.

(a) Position the clutch master cylinder assy properly, tighten
the clutch master cylinder assy nut positioned in the
driving cab. 42
(b) Tighten the clutch master cylinder assy nut positioned in

the engine room.
42
(c) Connect the clutch master cylinder tube to clutch master

cylinder and tighten the nut.
Torque: 25 N•m
(d) Connect the hose of brake fluid reservoir, then install

the clamp.
4. BLEED AIR FROM CLUTCH SYSTEM. (Refer to “Chapter 42 clutch - clutch fluid, bleeding”)
5. INSPECT AND ADJUST THE CLUTCH PEDAL HEIGHT. (Refer to “Chapter 42 clutch - clutch
pedal, adjustment”)
6. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR. (Refer to “Chapter 42 clutch - clutch fluid,
bleeding”)
CLUTCH - CLUTCH SLAVE CYLINDER ASSY 42-15
CLUTCH SLAVE CYLINDER ASSY

COMPONENTS
42
42
1 Dust Boot 4 Spring
2 Clutch Slave Cylinder Assy Push Rod 5 Clutch Slave Cylinder Housing
3 Piston 6 Bleeding Plug

42-16 CLUTCH - CLUTCH SLAVE CYLINDER ASSY
OVERHAUL
1. DRAIN CLUTCH FLUID COMPLETELY.
NOTE
Be careful not to splash the clutch fluid to person and painted surface or it must be washed off
immediately.
2. REMOVE CLUTCH SLAVE CYLINDER ASSY.

(a) Loosen the plug, then disconnect the hose of clutch
slave cylinder.
(b) Remove 2 bolts from clutch slave cylinder.
(c) Remove the clutch slave cylinder.

CLUTCH - CLUTCH SLAVE CYLINDER ASSY 42-17
3. INSTALL CLUTCH SLAVE CYLINDER ASSY.

(a) Position clutch cylinder assy properly, then install clutch
slave cylinder and tighten 2 bolts .
42
(b) Connect the hose of clutch slave cylinder, then tighten

the plug.
NOTE
Replace with a new washer before installing the plug. 42
4. BLEED AIR FROM CLUTCH SYSTEM. (Refer to “Chapter 42 clutch - clutch fluid, bleeding”)
5. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR. (Refer to “Chapter 42 clutch - clutch fluid,
bleeding”)
42-18 CLUTCH - CLUTCH SUB - ASSY
CLUTCH SUB - ASSY

COMPONENTS
1 Flywheel 6 Clutch Release Fork
2 Clutch Disk 7 Release Fork Support
3 Clutch Cover 8 Clutch Release Fork Dust Boot
4 Clutch Release Bearing 9 Transmission
5 Clutch Release Bearing Hub Clip

CLUTCH - CLUTCH SUB - ASSY 42-19
OVERHAUL
1. REMOVE TRANSMISSION ASSY. (Refer to “Chapter 41 transmission (R5M21-Z-GBA5) -
transmission assy, replacement”)
42
2. REMOVE CLUTCH RELEASE BEARING AND CLUTCH
RELEASE FORK.
(a) Remove clutch release bearing hub clip.
(b) Remove clutch release bearing.
42
(c) Remove clutch release fork.
3. REMOVE CLUTCH RELEASE FORK DUST BOOT.

4. REMOVE CLUTCH COVER.

(a) Make sure the marks on the clutch cover align with the
one on the flywheel.
(b) Diagonally loosen each bolt one turn at a time until
spring tension is released. Then remove 6 bolts.
(c) Remove the clutch cover.

NOTE
Do not drop the clutch disk assy.
5. REMOVE CLUTCH DISK.

NOTE
Keep the clutch disk away from oil and grease.
6. INSPECT CLUTCH DISK.

(a) Measure the rivet head depth by vernier caliper. Replace
with a new part if necessary.
Ultimate value: 0.3 mm
(b) Measure the runout of clutch disk by dial indicator.

42
(c) Check the surface of clutch disk for loose rivet, uneven
contact or adhesion of oil or grease. Replace with a new
part if necessary.
(d) Check the torsion spring for clearance and wear.Replace
with a new part if necessary.
7. INSPECT CLUTCH COVER.

(a) Measure depth and width of diaphragm spring for wear
by vernier caliper.
Specification: 0.5 mm 42
(b) Measure height of diaphragm spring. Replace with a new
part if necessary.
(c) Inspect the surface of clutch cover for wear and cracks.
Replace with a new part if necessary.
(d) Inspect the strap plate rivets for looseness. Replace with
a new clutch cover if necessary.
8. INSPECT FLYWHEEL.
(a) Measure the runout of flywheel by dial indicator.
Specification: 0.2 mm
9. INSPECT CLUTCH RELEASE BEARING.

(a) Inspect the clutch release bearing for wear, niose or
improper rotation.Inspect the friction surface between
clutch release bearing and diaphragm spring for
wear.Replace with a new part if necessary.
NOTE
The bearing is permanently lubricated and requires no
cleaning or lubrication.
CAUTION
• Inspect the internal surface and outside surface for

wear and shape change. Replace with a new part if
necessary.
• Inspect the friction surface of clutch release bearing
and release fork for wear. Replace with new part if
necessary.
10. INSPECT CLUTCH RELEASE FORK.

(a) Inspect the position of clutch release fork as arrows
show for wear and shape change. Replace with a new
part if necessary.
11. INSTALL CLUTCH DISK.

(a) Install clutch disk by special tool.
NOTE
Take care not to install clutch disk in the wrong direction.
12. INSTALL CLUTCH COVER.

(a) Make sure the marks on the clutch cover align with the
one on the flywheel.
(b) Install clutch cover by special tool.
(c) Diagonally tighten all 6 bolts.

Torque: 35 N•m
42
13. INSPECT AND ADJUST CLUTCH COVER.

(a) Inspect the height of diaphragm spring after installing.
Adjust the tip of diaphragm spring if necessary.
42
14. INSTALL CLUTCH RELEASE FORK DUST BOOT.
15. INSTALL CLUTCH RELEASE BEARING AND CLUTCH

RELEASE FORK.
(a) Apply grease to the position of clutch release fork as
arrows show.
or equivalent.
(b) Install clutch release fork.

CAUTION
Fasten the clutch release fork to the release fork support.
(c) Install clutch release bearing.

NOTE
Apply grease to the friction surface between clutch release
bearing and release fork before installing.
or equivalent.
(d) Install clutch release bearing hub clip.
16. INSTALL TRANSMISSION ASSY. (Refer to “Chapter 41 transmission (R5M21-Z-GBA5) -

transmission assy, replacement”)
STEERING COLUMN
51
STEERING SYSTEM.......................................................................... 51-1
PRECAUTION.............................................................................. 51-1
COMPONENTS ........................................................................... 51-5 51
ON-VEHICLE INSPECTION ........................................................ 51-6
STEERING WHEEL ASSY................................................................. 51-7
ADJUSTMENT ............................................................................. 51-7
OVERHAUL ................................................................................. 51-8 51
COMBINATION SWITCH ASSY ...................................................... 51-13
COMPONENTS ......................................................................... 51-13
REPLACEMENT ........................................................................ 51-14
STEERING COLUMN ASSY ............................................................ 51-19
OVERHAUL ............................................................................... 51-19
STEERING PROPELLER SHAFT ASSY......................................... 51-26
51
OVERHAUL ............................................................................... 51-26
STEERING COLUMN BEAM WELDING ASSY .............................. 51-30
REPLACEMENT ........................................................................ 51-30
STEERING COLUMN - STEERING SYSTEM 51-1
STEERING SYSTEM
STEERING COLUMN
PRECAUTION
1. STEERING SYSTEM PRECAUTION. 51
(a) Care must be taken when replacing parts.
(b) Incorrect replacement may affect the performance of the steering system and result in driving
dangerously.
2. SRS SYSTEM PRECAUTION.
(a) Some MPX vehicles are equipped with SRS (Supplemental Restraint System) such as the driver
airbag.
(b) Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly
deploy during servicing, even a serious accident.
(c) Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the
precaution for the supplemental restraint system. (Refer to “Chapter 62 supplemental restraint system -
supplemental restraint system, precaution”)
51
51-2 STEERING COLUMN - STEERING SYSTEM

cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.
1. Front axle (Overload) -
Chapter 33 tire and wheel - tire and wheel,

2. Tire (Insufficient pressure) on-vehicle inspection
Chapter 52 power steering - power steering

3. Power steering fluid level (Low) system, on-vehicle inspection
4. Steering fluid reservior (Filter jam) -

5. Power steering system (Leakage) pump, replacement
Steering heavily Chapter 52 power steering - power steering
6. Drive belt (Loose or skidding) system, on-vehicle inspection
Chapter 31 front suspension - front wheel

7. Front wheel alignment (Incorrect) alignment, adjustment
Chapter 34 axle and propeller shaft -

8. Steering knuckle (Worn) steering knuckle, overhaul

9. Steering knuckle arm (Worn) steering knuckle, overhaul

10. Ball joint (Worn) steering knuckle, overhaul
Chapter 51 steering column - steering

1. Steering column (Bent) column assy, inspection

2. Steering propeller shaft (Deformed) propeller shaft assy, inspection

Steering heavily 3. Power steering pump (Worn or damaged) system, on-vehicle inspection
Chapter 52 power steering - steering gear

4. Steering gear assy (Damaged) assy, inspection

5. Power steering line assy (Jam) line assy, replacement

51
2. Tire (Different pressure) on-vehicle inspection


Wandering 4. Steering knuckle arm (Worn) steering knuckle, overhaul

5. Steering column (Loose or worn) column assy, inspection
6. Steering propeller shaft (U-joint loose or Chapter 51 steering column - steering

worn) propeller shaft assy, inspection

7. Steering gear assy (Loose or damaged) assy, inspection
51
1. Tire (Insufficient pressure) on-vehicle inspection

2. Drive belt (Loose or skidding) system, on-vehicle inspection
Chapter 52 power steering - steering fluid,

3. Power steering system (Invading air) bleed and purify

4. Return hose (Curving or jam) line assy, replacement

Poor return 5. Front wheel alignment (Incorrect) alignment, adjustment



8. Power steering pump (Worn or damaged) system, on-vehicle inspection


Chapter 51 steering column - steering wheel
1. Steering wheel (Worn) assy, replacement


Excessive 3. Steering knuckle (Worn) steering knuckle, overhaul
steering wheel
free play Chapter 34 axle and propeller shaft -
4. Ball joint (Worn) steering knuckle, overhaul
Chapter 34 axle and propeller shaft - hub

5. Front hub bearing (Worn and steering knuckle, on-vehicle inspection




Abnormal noise
5. Steering propeller shaft (Worn) propeller shaft assy, inspection

6. Power steering pump (Worn or damaged) system, on-vehicle inspection


8. Power steering line assy (Jam) line assy, replacement


Steering not Chapter 51 steering column - steering

smooth 3. Steering column (Worn) column assy, inspection


5. Steering gear assy (Worn or damaged) assy, inspection
COMPONENTS
51
51
1 Steering Wheel Assy 7 Lower Propeller Shaft Seal Housing
2 Steering Column Assy 8 Flat Washer
3 Nut 9 Spring Washer
4 Bolt 10 Nut
5 Steering Propeller Shaft Assy 11 Steering Gear Assy
6 Nut
ON-VEHICLE INSPECTION
1. CHECK STEERING WHEEL FREE PLAY.
(a) Stop the vehicle.
(b) Turn the steering wheel to its straight position and face the
tires straight ahead.
(c) Rock the steering wheel gently left and right, check the
steering wheel free play.
Free play: ± 10 °
If the free play is out of the specification, then:
• Inspect interrelated parts. (Refer to ”Chapter 51 steering
column - steering system, problem symptoms table”)
• Inspect the maximum front wheel steering angle, adjust it if
necessary. (Refer to “Chapter 31 front suspension - front
wheel alignment, adjustment”)
2. CHECK THE OFF TRACK.

(a) Drive straightly along the center line of the proving road at the speed of 40 Km/h.
(b) Release the steering wheel and continue sliding straightly for 30 m.
(c) Measure the offset.
Offset LH: ＜ 2 m
Offset RH: ＜ 1 m
STEERING COLUMN - STEERING WHEEL ASSY 51-7
STEERING WHEEL ASSY

ADJUSTMENT
51
1. STEERING WHEEL UP-DOWN ADJUSTMENT.
(a) Pull the handle forward and hold it.
(b) Adjust the steering wheel up and down.

Adjustable distance: 49 mm
WARNING
51
• Be sure to adjust the steering wheel towards your chest,
instead of the head or neck.
• Simultaneously adjust the driver seat. make sure the
distance between steering wheel and your chest is
more than 250 mm. (Refer to “Chapter 84 seat -
Driver / assistant driver seat, adjustment”)
• Do not perform this operation when the vehicle is
running.
(c) Release the handle.

WARNING
Make sure the steering wheel is locked completely without
clearance.
51-8 STEERING COLUMN - STEERING WHEEL ASSY
OVERHAUL
1. PRECAUTION. (Refer to “Chapter 51 steering column - steering system, precaution”)
2. DISCONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging -
battery, replacement”)
3. DISCONNECT BATTERY POSITIVE CABLE. (If airbag is equipped, refer to “Chapter 20 starting
and charging - battery, replacement”)
4. REMOVE HORN SWITCH ASSY.

(a) Turn the steering wheel to its straight position and face the
(b) The vehicle without airbag:

Remove the horn switch assy directly.
(c) The vehicle with airbag:

• Using an allen wrench (key), loosen 2 bolts at the bottom
of steering wheel.
• Remove the horn switch assy.

• Turn the horn switch assy over.

• Disconnect the clock spring wire harness connector.
• Disconnect the horn switch wire harness connector.
51
CAUTION
• Do not drag the clock spring wire harness.
• Do not disassemble the horn switch assy.
• When removing the horn switch assy or handling a new
horn switch assy, it should be placed with the pad top
surface upward. Placing it with the pad top surface
downward may lead to a serious accident if the airbag 51
accidentally inflates. Also, do not place horn switch
assy on top of one another.
5. REMOVE STEERING WHEEL ASSY.

(a) Disconnect the horn switch wire harness connector.
NOTE
• This procedure only applies to the vehicle without
airbag.
• For the vehicle with airbag, skip this procedure.
(b) Loosen the nut.

NOTE
Store it carefully to prevent it from being missing.
(c) Mark on the steering wheel and steering column assy.

CAUTION
Make sure the marks are clear.
(d) Pull out the steering wheel from the steering column.
6. INSPECT STEERING WHEEL ASSY.

(a) Check the steering wheel for warp, micro-cracks or fracture.
(b) Check the center spline for deformation or damage on above 2 teeth.
If any fault is detected, replace with a new steering wheel.
7. INSTALL STEERING WHEEL ASSY.

(a) Align the marks on the steering wheel assy and steering
column assy.
(b) Install the steering wheel.
CAUTION
• Be sure to perform this operation according to the
marks.
• Make sure the tires face ahead straightly.
(c) Tighten the nut.

Torque: 40 ～ 50 N•m
51
(d) Connect the horn switch wire harness connector.

NOTE
• This procedure only applies to the vehicle without
airbag.
• For the vehicle with airbag, skip this procedure.
51
8. INSPECT STEERING WHEEL TURNING FORCE.

(a) Using a spring scales, pull the steering wheel rim
tangentially, measure the steering wheel turning force
(engine stopped).
Steering wheel turning force (engine stopped): ＜ 200 N
If steering wheel turning force exceeds the maximum, inspect
interrelated parts. (Refer to “Chapter 51 steering column -
steering system, problem symptoms table”)
9. INSTALL HORN SWITCH ASSY.

(a) The vehicle without airbag:
Install the horn switch assy directly.
(b) The vehicle with airbag:

• Connect the clock spring wire harness connector.
• Connect the horn switch wire harness connector.
CAUTION
• Never use the airbag parts removed from another
vehicle. When replacing, use a new one.
• If the horn switch assy has been dropped, or there are
cracks, dents or any faults in the case or connector,
replace the horn switch assy with a new one.
• Do not drag the clock spring wire harness. Make sure

the wire harness does not interfere with parts around.
NOTE
If hear a “click”, the connector is connected completely.
• Install the horn switch assy.
CAUTION
• There should be no interference between the horn
switch assy and steering wheel.
• The clearance should be uniform all the way around
when the horn switch assy is installed on the
steering wheel.
• Using an allen wrench (key), tighten 2 bolts at the bottom

of steering wheel.
Torque: 10 N·m
10. CONNECT BATTERY POSITIVE CABLE. (If airbag is equipped, refer to “Chapter 20 starting and
charging - battery, replacement”)
11. CONNECT BATTERY NEGETIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,
replacement”)
12. INSPECT SRS WARNING LIGHT. (If equipped, refer to “Chapter 04 diagnostics - supplemental
restraint system, precheck”, “Chapter 04 diagnostics - supplemental restraint system, SRS
warning light is always on”, “Chapter 04 diagnostics - supplemental restraint system, SRS
warning light is inoperative”)
STEERING COLUMN - COMBINATION SWITCH ASSY 51-13
COMBINATION SWITCH ASSY

COMPONENTS
51
51
1 Combination Switch Upper Cover 5 Screw
2 Combination Switch Assy 6 Combination Switch Lower Cover
3 Screw 7 Steering Column Assy
4 Screw
51-14 STEERING COLUMN - COMBINATION SWITCH ASSY
REPLACEMENT
4. REMOVE HORN SWITCH ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,
overhaul”)
5. REMOVE STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,
overhaul”)
6. REMOVE COMBINATION SWITCH ASSY.

(a) Loosen 3 screws.
(b) Remove combination switch upper and lower covers.
(c) The vehicle with airbag:

• Loosen 4 screws and remove the clock spring.
51
(d) Disconnect 2 conectors.

• Disconnect the front combination lamp dimmer switch
connector.
• Disconnect the wiper and washer switch connector.
51
(e) Loosen 3 screws.
(f) Remove the combination switch assy.
7. INSTALL COMBINATION SWITCH ASSY.

(a) Install the combination switch assy.
(b) Tighten 3 screws.
(c) Connect 2 connectors:

• Connect the front combination lamp dimmer switch
connector.
• Connect the wiper and washer switch connector.
(d) The vehicle with airbag:

• Install the clock spring and tighten 4 screws.
CAUTION
• Check for the fracture on the spiral cable. There should
be unbroken on the insulating barrier.
• Make sure the cable rolls smoothly without noise.
NOTE
The cable will rotate more than 5.3 turns.

(e) Install the combination switch upper and lower covers.

NOTE
Make sure the covers are positioned properly.
(f) Tighten 3 screws.
51
(g) The vehicle with airbag:

Center the clock spring.
• Check that the ignition switch is in the “OFF” position.
• Check that the battery positive and negetive terminals
are disconnected.
CAUTION
Do not start the operation within 90 seconds after 51
disconnecting the cables.
NOTE
There is an information label on the clock spring.
Follow the instructions on the label.
• Turn the cable counterclockwise by hands until it
becomes hard to turn.
• Rotate the cable clockwise about 2.5 turns to align the

marks.
NOTE
The cable will rotate above 2.5 turns to either left or right off
the center.
NOTE
For a new clock spring:
• It is located at the center position by clip.
• Do not forget to remove the clip after installing a new
clock spring.
8. INSTALL STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,
overhaul”)
9. INSTALL HORN SWITCH ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,
overhaul”)
11. CONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,
replacement”)
STEERING COLUMN - STEERING COLUMN ASSY 51-19
STEERING COLUMN ASSY

OVERHAUL
1. PRECAUTION. (Refer to “Chapter 51 steering column - steering system, precaution”) 51
overhaul”)
overhaul”)
6. REMOVE CLOCK SPRING. (Refer to “Chapter 62 supplemental restraint system - clock spring,
replacement”)
7. REMOVE COMBINATION SWITCH ASSY. (Refer to “Chapter 51 steering column - combination
switch assy, replacement”)
51
8. REMOVE STEERING COLUMN LOWER COVER.
(a) Hold the engine hood lock switch.
(b) Loosen 2 screws.
(c) Loosen 3 screws.

51-20 STEERING COLUMN - STEERING COLUMN ASSY
(d) Remove the steering column lower cover.
(e) Disconnect the diagnosis wire harness connector.
(f) Store the steering column lower cover carefully.

CAUTION
Do not drag the engine hood lock cable.
(g) Remove the engine hood lock handle from the cable.
CAUTION
• Do not drag the engine hood lock cable.
• Be sure to store the engine hood lock handle
carefully.
9. REMOVE IGNITION SWITCH ASSY. (Refer to “Chapter 91 vehicle control system -

removal&installation and disassembly&reassembly”)
10. REMOVE STEERING COLUMN ASSY.

(a) Mark on the steering column and steering propeller shaft.
CAUTION
(b) Loosen the bolt.
51
(c) Pull the steering propeller shaft down from the steering
column.
51
(d) Remove 2 harness clips.

(e) Loosen 4 nuts.

(f) Remove the steering column assy.
NOTE
When storage, cover the splines with gum cap or soft cloth
on the both sides to prevent damage.
CAUTION
Be sure to store the steering column carefully, especially
the splines.
11. INSPECT STEERING COLUMN ASSY.

(a) Inspect the splines.
• Check for rusting, crack and fracture.
• Check for deformation or damage for more than 2 teeth.
If any fault is detected, replace with a new steering column assy.
12. INSTALL STEERING COLUMN ASSY.

(a) Positon the steering column assy properly.
(b) Tighten 4 nuts.
Torque: 41 ～ 51 N·m
(c) Install 2 harness clips.

NOTE
Replace the harness clips when necessary.
51
51
(d) Install the steering propeller shaft to the steering column

assy according to the marks.
CAUTION
Be sure to perform this operation according to the marks.
(e) Tighten the bolt.

13. INSTALL IGNITION SWITCH ASSY. (Refer to “Chapter 91 vehicle control system - removal &
installation and disassembly & reassembly”)
14. INSTALL STEERING COLUMN LOWER COVER.

(a) Connect the engine hood lock handle with the cable.
CAUTION
(b) Put the engine hood lock handle through the mounting
hole of the steering column lower cover.
(c) Connect the diagnosis wire harness connector.
CAUTION
(d) Install the steering column lower cover.
(e) Tighten 3 screws.

(f) Hold the engine hood lock switch and tighten 2 screws.
51
51
15. INSTALL COMBINATION SWITCH ASSY. (Refer to “Chapter 51 steering column - combination
16. INSTALL CLOCK SPRING. (Refer to “Chapter 62 supplemental restraint system - clock spring,
replacement”)
overhaul”)
overhaul”)
replacement”)
51-26 STEERING COLUMN - STEERING PROPELLER SHAFT ASSY
STEERING PROPELLER SHAFT ASSY

OVERHAUL
1. REMOVE ENGINE LOWER GUARD PLATE.
(a) Loosen 8 bolts.
(b) Remove the engine lower guard plate.
2. REMOVE STEERING PROPELLER SHAFT ASSY.

(a) Mark on the steering propeller shaft and the steering
gear assy.
CAUTION
(c) Pull the steering propeller shaft up from the steering

gear.
STEERING COLUMN - STEERING PROPELLER SHAFT ASSY 51-27
(d) Loosen 2 nuts.
51
(e) Remove the lower propeller shaft seal housing.
51
(f) Mark on the steering column and the steering propeller

shaft.
CAUTION
(g) Loosen the bolt.
(h) Pull the steering propeller shaft down from the steering
column.
51-28 STEERING COLUMN - STEERING PROPELLER SHAFT ASSY
(i) Remove the steering column assy and lower propeller shaft seal housing.
CAUTION
Be sure to store the steering propeller shaft carefully to prevent damage, expecially the splines.
3. INSPECT THE STEERING COLUMN ASSY.

(a) Check the steering column assy for bend.
Replace with a new steering propeller shaft when necessary.
(b) Inspect the splines, splined sleeves and U-joint yoke.
• Check for warp, micro-cracks or fracture.
• Check for deformation or damage for more than 2 teeth.
If any fault is detected, replace with a new steering propeller shaft assy.
(c) Inspect the steering propeller shaft U-joint.
• Check whether the U-joint rolls smoothly.
Replace with a new steering propeller shaft when necessary.
• Measure the clearance between the cross shaft necks and bearings.
Clearance: ≤ 0.2 mm
If the clearance exceeds the manximum, replace with a new steering propeller shaft.
4. INSTALL STEERING PROPELLER SHAFT.
(a) Put the lower propeller shaft seal housing on the steering propeller shaft.
(b) Insert the steering propeller shaft assy.
CAUTION
Make sure the steering propeller shaft assy is in the correct direction.
(c) Install the steering propeller shaft to the steering column

according to the marks.
CAUTION
(d) Tighten the bolt.

STEERING COLUMN - STEERING PROPELLER SHAFT ASSY 51-29
(e) Position the lower propeller shaft seal housing properly.
51
(f) Tighten 2 nuts.

51
(g) Install the steering propeller shaft to the steering gear

CAUTION
(h) Tighten the bolt.

5. INSTALL ENGINE LOWER GUARD PLATE.

(a) Position the engine lower guard plate properly.
51-30 STEERING COLUMN - STEERING COLUMN BEAM WELDING ASSY
STEERING COLUMN BEAM WELDING ASSY

REPLACEMENT
overhaul”)
overhaul”)
replacement”)
8. REMOVE IGNITION SWITCH ASSY. (Refer to “Chapter 91 vehicle control system - removal &
9. REMOVE STEERING COLUMN ASSY. (Refer to “Chapter 51 steering column - steering column
assy, overhaul”)
10. REMOVE STEERING COLUMN BEAM WELDING

ASSY.
(a) Loosen 2 screws attaching dashboard to steering column
beam welding assy.
(b) Disconnect the electric appliance switch panel LH

connector.
STEERING COLUMN - STEERING COLUMN BEAM WELDING ASSY 51-31
(c) Remove the electric appliance switch panel LH.

NOTE
This operation may make the next step to be convenient.
51
(d) Using screwdriver, pry 2 clips.

NOTE
The operation becomes convenient after the previous step.
51
(e) Remove the multi-function controller (3-in-1).

NOTE
This operation may make the next step to be convenient.
(f) Loosen a nut and 2 bolts attaching steering column

beam welding assy to side wall welding assy LH.
NOTE
There is more space for this operation after the previous
step.
(g) Loosen the 2 bolts attaching steering column beam welding

assy to body lower welding assy.
(h) Loosen the bolt attaching brake pedal assy to steering

column beam welding assy.
(i) Loosen the 2 bolts attaching the accelerator pedal to

steering column beam welding assy.
(j) Remove the steering column beam welding assy.

CAUTION
Be careful. Do not damage the parts and wire harness around.
11. INSTALL STEERING COLUMN BEAM WELDING ASSY.
(a) Positon the steering column beam welding assy properly.
CAUTION
• Be careful. Do not damage the parts and wire harness around.
• Be sure to arrange the wire harness around without interference.
(b) Tighten the 2 bolts attaching the accelerator pedal to

steering column beam welding assy.
51
51
(c) Tighten the bolt attaching brake pedal assy to steering

column beam welding assy.
(d) Tighten 2 bolts attaching steering column beam welding

assy to body lower welding assy.
(e) Tighten a nut and 2 bolts attaching steering column

beam welding assy to side wall welding assy LH.
(f) Install the multi-function controller (3-in-1).

NOTE
If hear 2 “clicks”, the multi-function controller (3-in-1) is
installed correctly.
(g) Install the electric appliance switch panel LH.
(h) Connect the electric appliance switch panel LH connector.
(i) Tighten 2 screws attaching dashboard to steering column

beam welding assy.
12. INSTALL STEERING COLUMN ASSY. (Refer to “Chapter 51 steering column - steering column
assy, overhaul”)
13. INSTALL IGNITION SWITCH ASSY. (Refer to “Chapter 91 vehicle control system - 51
removal&installation and disassembly&reassembly”)
replacement”)
overhaul”)
overhaul”)
replacement”) 51
MEMO
POWER STEERING
52
POWER STEERING SYSTEM ........................................................... 52-1
PRECAUTION.............................................................................. 52-1
COMPONENTS ........................................................................... 52-5 52
STEERING FLUID ............................................................................ 52-14
REPLACEMENT ........................................................................ 52-14
BLEEDING AND PURIFYING.................................................... 52-17 52
POWER STEERING PUMP WITH FLUID RESERVIOR ASSY....... 52-19
REPLACEMENT ........................................................................ 52-19
POWER STEERING LINE ASSY ..................................................... 52-27
REPLACEMENT ........................................................................ 52-27 52
STEERING GEAR ASSY ................................................................. 52-30
OVERHAUL ............................................................................... 52-30
STEERING FLUID RESERVIOR...................................................... 52-36
REPLACEMENT ........................................................................ 52-36
POWER STEERING - POWER STEERING SYSTEM 52-1
POWER STEERING SYSTEM

POWER STEERING
PRECAUTION
1. POWER STEERING SYSTEM PRECAUTION. 52
(a) Take care when replacing parts.
(b) Incorrect replacement may affect the performance of the steering system and result in driving
dangerously.
(c) Be sure to use the specified steering fluid.
Steering fluid: ATF- Ⅲ
(d) Replace the steering fluid and clean the fluid reservior filter in the primal 2500 Km for a new steering
gear assy. Then repeat these two operations in each following 5000 Km or 1 year. (Refer to “Chapter 52
power steering - steering fluid, replacement”)
(e) Check the steering fluid level and whether the fluid goes bad or exist excessive impurities every month.
(Refer to “Chapter 52 power steering - power steering system, on-vehicle inspection”)
(f) Regularly check at least each 5000 Km. 52
• Check for loose.
• Check steering system operation.
52-2 POWER STEERING - POWER STEERING SYSTEM

1. Front axle (Overload) -
Chapter 33 tire and wheel - tire and

2. Tire (Insufficient pressure) wheel, on-vehicle inspection
Chapter 52 power steering - power

3. Power steering fluid level (Low) steering system, on-vehicle inspection

5. Power steering system (Leakage) steering pump, replacement
Steering heavily Chapter 52 power steering - power
6. Drive belt (Loose or skidding) steering system, on-vehicle inspection

7. Front wheel alignment (Incorrect) alignment, adjustment


9. Steering knuckle arm (Worn) steering knuckle, overhaul

10. B-joint (Worn) steering knuckle, overhaul



Steering heavily 3. Power steering pump (Worn or damaged) steering system, on-vehicle inspection


5. Power steering line assy (Jam) steering line assy, replacement

52
2. Tire (Different pressure) wheel, on-vehicle inspection


Wandering 4. Steering knuckle arm (Worn) steering knuckle, overhaul

5. Steering column (Loose or worn) column assy, inspection

52
1. Overload -
Steering gear assy 2. Operation (Incorrect) (Turn the steering -

overheat wheel to full lock position for more than 4
(It exceeds the seconds)
enviromental
temperature more 3. Power steering pump (Exsessive flow) steering system, on-vehicle inspection
than 65 ℃ )
4. Power steering line assy (Deformation or Chapter 52 power steering - power
jam) steering line assy, replacement

1. Tire (Insufficient pressure) wheel, on-vehicle inspection

2. Drive belt (Loose or skidding) steering system, on-vehicle inspection

3. Power steering system (Invading air) bleeding and purifying

4. Return hose (Curving or jam) steering line assy, replacement

Poor return 5. Front wheel alignment (Incorrect) alignment, adjustment



8. Power steering pump (Worn or damaged) steering system, on-vehicle inspection


1. Steering wheel (Worn) wheel assy, replacement


Excessive steering
wheel free play Chapter 34 axle and propeller shaft -
4. B-joint (Worn) steering knuckle, overhaul
Chapter 34 axle and propeller shaft - hub

5. Front hub bearing (Worn and steering knuckle, on-vehicle
inspection




Abnormal noise

6. Power steering pump (Worn or damaged) steering system, on-vehicle inspection


8. Power steering line assy (Jam) steering line assy, replacement



Steering irregularity 3. Steering column (Worn) column assy, inspection


5. Steering gear assy (Worn or damaged) assy, inspection
COMPONENTS
GASOLINE VEHICLES
52
52
1 Cotter Pin 11 Clamp
2 Slotted Nut 12 Flat Washer
3 Steering Gear Assy 13 Bolt
4 Flat Washer 14 Washer
5 Spring Washer 15 Bolt
6 Bolt 16 V-Ribbed Belt
7 Bolt 17 High-pressure Line Assy
8 Bolt 18 Low-pressure Line Assy
9 Tensioner With Bracket Assy. 19 Steering Propeller Shaft Assy
Power Steering Pump With Fluid 20 Engine Crankshaft Belt Pulley

10
Reservior Assy
DIESEL VEHICLES
1 Cotter Pin 13 Flat Washer
2 Nut 14 Spring Washer
3 Steering Gear Assy 15 Bolt
4 Flat Washer 16 Flat Washer
5 Spring Washer 17 Spring Washer
6 Bolt 18 Bolt
7 Bolt 19 Flat Washer
8 Bolt 20 Bolt
Power Steering Pump With Fluid 21 Low-pressure Line Assy

9
Reservior And Bracket Assy
22 Steering Propeller Shaft Assy
10 Clamp
23 Engine Crankshaft Belt Pulley
11 High-pressure Line Assy
12 V-belt
1. INSPECT DRIVE BELT.
(a) Visual check for exsessive wear, etc. 52
If any fault is found, replce the drive belt.
NOTE
• Cracks on the rib side of a belt are considered
acceptable. If the missing chunks from the ribs are
found on the belt, it should be replaced.
• Inspect the V-ribbed belt(applied to gasoline
vehicles) by the same procedures as the V-belt
(applied to diesel vehicles), although the appearance
may be different.
(b) Check the deflection.

• Apply a force of 98 N to middle of the drive belt. 52
Deflection (Gasoline vehicle) : ≤ 5 mm
Deflection (Diesel vehicle) : 5.5 ～ 8.5 mm
WARNING
Make sure the engine is stopped before performing this
operation.
2. CHECK STEERING FLUID LEVEL.

(a) Park the vehicle on level road.
(b) Check the steering fluid level.

• Fill the steering fluid if necessary. (Refer to “Chapter 52
power steering - steering fluid, replacement”)
NOTE
• Make sure the egnine is stopped.
• Check that the fluid level is within the COLD range, if
the fluid is cold.
• Check that the fluid level is within the HOT range, if
the fluid is hot.
(c) Start the engine and run it at idle.

(d) Turn the steering wheel fully to the right and left several
times to raise fluid temperature.
Fluid temperature: - 40 ～ 120 ℃
CAUTION
Make sure the time when steering wheel stays at full lock
position will not exceed 4 seconds, otherwise it will damage
the power steering pump.
NOTE
Lift front wheels off the ground with jack or lift.
(e) Check for foam and emulsification.

If foam or emulsification is identified, bleed the power
steering sysytem. (Refer to “Chapter 52 power steering -
steering fluid, bleeding and purifying”)
(f) With the engine idling, measure the steering fluid level in
the fluid reservior.
NOTE
Check that the fluid level is within the HOT range, if the fluid
is hot.
(g) Stop the engine.
(h) Wait a few minutes, measure the steering fluid level in
the fluid reservior again.
NOTE
the fluid is cold.
the fluid is hot.
(i) Check steering fluid level difference between the levels

obtained in procedure (f) and (h).
Steering fluid level difference: ≤ 5 mm
If the difference is out of the specification, bleed the power
steering system. (Refer to “Chapter 52 power steering - steering
fluid, bleeding and purifying”)
(j) Check the steering fluid level finally and fill the steering
fluid if necessary.
3. CHECK STEERING FLUID PRESSURE.

(a) Loosen 4 bolts and remove the engine cover.
52
(b) Loosen 2 bolts and remove the air intake duct.
52
(c) Separate the high-pressure tube from power steering

pump.
NOTE
Be sure to keep it clean and prevent dirt entry.
• Gasoline vehicles.
• Diesel vehicles.
(d) Connect the SST, as shown in the illustration.

CAUTION
• Be sure to keep it clean and prevent dirt entry.
• Check that the valve of the SST is in “OPEN” posi-
tion.
(e) Bleed the power steering system. (Refer to “Chapter 52

power steering - steering fluid, bleed and iurity”)
(f) Start the engine and run it at idle.
(g) Turn the steering wheel fully to the right and left several
times to raise fluid temperature.
Fluid temperature: - 40 ～ 120 ℃
CAUTION 52
NOTE
Lift front wheels off the ground with jack or lift.
(h) With the engine idling, close the valve of the SST.
(i) Observe the reading on the SST.
CAUTION
• Do not close the valve for more than 4 seconds.
• Do not let the fluid temperature become too high. 52
(j) With the engine idling, open the valve of the SST.
(k) Measure the fluid pressure when engine is running at
1000 RPM and 3000 RPM.
CAUTION
Do not turn the steering wheel.
(l) With the engine idling and the valve fully opened, turn
the steering wheel to full lock position.
(m) Observe the reading on the SST.
Pressure: ≤ 8 MPa
CAUTION
• Do not close the valve for more than 4 seconds.
• Do not let the fluid temperature become too high.
(n) Disconnect the SST.

CAUTION
(o) Coat the sealant on the high-pressure tube connector.

(p) Connect the high-pressure tube to power steering pump.

CAUTION
(q) Install the air intake duct and tighten 2 bolts.

(r) Install the engine cover and tighten 4 bolts.
(s) Bleed the power steering system. (Refer to “Chapter 52

power steering - steering fluid, bleeding and purifying”)。
4. INSPECT STEERING WHEEL TURNING FORCE.

52
(b) Remove the horn switch assy. (Refer to “Chapter 51 steer-

ing column - steering wheel assy, overhaul”)
(d) Using a torque wrench, measure the steering wheel turning

force (engine idling) 52
Steering wheel turning force (engine idling): ＜ 45 N
NOTE
Take the tire type, pressure and contact surface into your
consideration before diagnosis.
(e) Tighten the steering wheel lock nut。

Torque: 40 ～ 50 N•m
(f) Install the horn switch assy. (Refer to “Chapter 51 steer-

ing column - steering wheel assy, overhaul”)
5. CHECK THE OFF TRACK.

(a) Driving straightly along the center line of the proving road at the speed of 40 Km/h.
(b) Release the steering wheel and continue sliding straightly for 30 m.
(c) Measure the offset.
Offset LH: ＜ 2 m
Offset RH: ＜ 1 m
52-14 POWER STEERING - STEERING FLUID
STEERING FLUID
REPLACEMENT
1. PRECAUTION. (Refer to “Chapter 52 power steering - power steering system, precaution”)
2. DRAIN STEERING FLUID.
(a) Lift front wheels off the ground with jack or lift.
(b) Loosen 8 bolts and remove the engine lower guard plate.
(c) Turn counterclockwise and remove the steering fluid

reservior cap.
CAUTION
(d) Loosen the clamp and separate the low-pressure hose

from steering gear assy.
CAUTION
(e) Start the engine and run it at idle.

(f) Drain the steering fluid.
(g) Turn the steering wheel fully to the right and left several
times until steering fluid is drained fully.
CAUTION
• Do not perform this operation for more than 10
seconds.
• Make sure the time when steering wheel stays at full
lock position will not exceed 4 seconds, otherwise it
will damage the power steering pump.
(h) Stop the engine.
POWER STEERING - STEERING FLUID 52-15
3. FILL STEERING FLUID.

(a) Connect the low-pressure hose to steering gear assy
and tighten the clamp.
Torque: 40 ～ 45 N·m 52
CAUTION
(b) Fill the steering fluid.

Volumn: 0.4 L
(d) Turn the steering wheel fully to the right and left several 52
times until the fluid will not be emulsifiable and the level
will no longer drop down.
CAUTION
(e) Check the steering fluid level and fill the steering fluid if
necessary. (Refer to “Chapter 52 power steering - power
steering system, on-vehicle inspection”)
NOTE
the fluid is cold.
the fluid is hot.
(f) Install and turn clockwise the reservior cap.

CAUTION
(g) Stop the engine.
(h) Position the engine lower guard plate properly.

(i) Tighten 8 bolts.
(j) Lower the vehicle.

POWER STEERING - STEERING FLUID 52-17
BLEEDING AND PURIFYING

1. PRECAUTION. (Refer to “Chapter 52 power steering - power steering system”)
2. BLEED POWER STEERING SYSTEM.
52
(b) Turn counterclockwise and remove the steering fluid

reservior cap.
CAUTION
52
(c) Turn the steering wheel fully to the right and left several
times.
(d) Start the engine and run it at idle.
(e) Turn the steering wheel.

• Turn the steering wheel to left full lock position for 2 ～ 3
seconds, then turn to the opposite full lock position for 2 ～
3 seconds.
• Repeat the previous procedure several times.
CAUTION
(f) Stop the engine.
(g) Check for foam or emulcification.

If foam or emulsification is identified, repeat the
procedures (c) ～ (e).
NOTE
If the system has to be bled twice becauce of foam or
emulcification, check for fluid leakage in the system.
(h) Check the steering fluid level and fill the steering fluid if
necessary. (Refer to “Chapter 52 power steering - power
steering system, on-vehicle inspection”)
NOTE
the fluid is cold.
the fluid is hot.
(i) Install and turn clockwise the reservior cap.

CAUTION
(j) Stop the engine.

(k) Lower the vehicle.
3. PURIFY POWER STEERING SYSTEM.

(b) Start the engine and run it at idle.
(c) Turn the steering wheel fully to the right and left several times.
CAUTION
Make sure the time when steering wheel stays at full lock position will not exceed 4 seconds, otherwise
it will damage the power steering pump.
(d) Check for abnormal noise.
If abnormal noise is identified, bleed the power steering system. (Refer to “Chapter 52 power steering -
steering fluid, bleeding and purifying”)
(e) Repeat procedures (c) ～ (d) until the noise disappears.
(f) Stop the engine.
(g) Lower the vehicle.
(h) Check for jam and dirt in the steering fluid reservior filter.
Clean or replace the filter if necessary.
POWER STEERING - POWER STEERING PUMP WITH FLUID RESERVIOR ASSY 52-19
POWER STEERING PUMP WITH FLUID RESERVIOR ASSY

REPLACEMENT
CAUTION 52
• Generally, treat the power steering pump with fluid reservior assy as a whole. Do not separate
the fluid reservior from the power steering pump unless absolutely necessary.
• Do not disassemble the power steering pump because of its high precision.
2. DRAIN FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”)
3. REMOVE ENGINE COVER.

(a) Loosen 4 bolts and remove the engine cover.
52
4. REMOVE AIR INTAKE DUCT.

(a) Loosen 2 bolts and remove the air intake duct.
5. SEPARATE POWER STEERING LINE ASSY FROM

FLUID RESERVIOR.
(a) Gasoline vehicles:
• Separate the high-pressure tube from the power steering
pump.
CAUTION
• Loosen the clamp and separate the low-pressure hose
from the steering fluid reservior.
CAUTION
52-20 POWER STEERING - POWER STEERING PUMP WITH FLUID RESERVIOR ASSY
(b) Diesel vehicles:

pump.
CAUTION
CAUTION
6. REMOVE DRIVE BELT.

• Remove the retaining bolt from the upstream oxygen
sensor bracket.
• Position the upstream oxygen sensor wire harness prop-

erly to expose the tensioner adjusting bolt.
• Loosen the retaining bolt from the tensioner.
• Adjust the tensioner adjusting bolt to loosen the drive

belt.
• Remove the drive belt (ribbed belt).
52

• Loosen 2 retaining bolts from the power steering pump.
52
• Adjust the tensioner adjusting bolt to loosen the drive

belt.
• Remove 2 drive belts (V-belt).
7. REMOVE POWER STEERING PUMP WITH FLUID

RESERVIOR ASSY.
• Loosen the bolt.
• Remove the power steering pump pulley.
• Loosen 3 bolts.
• Remove the power steering pump with fluid reservior assy.

• Loosen 2 bolts.
• Remove the power steering pump with fluid reservior assy.

8. INSTALL POWER STEERING PUMP WITH FLUID

RESERVIOR ASSY.
52
• Position the power steering pump with fluid reservior assy
properly.
NOTE
Install the power steering pump pulley temporarily, check
whether the pump pulley is on the same plane with the
engine crankshaft pulley and tensioner .
• Tighten 3 bolts.
52
• Install the power steering pump pulley.

CAUTION
Make sure the power steering pump pulley is on the same
plane with the engine crankshaft pulley and tensioner.
• Tighten the bolt.

• Position the power steering pump with fluid reservior assy
properly.
CAUTION
Make sure the power steering pump pulley is on the same
plane with the engine crankshaft pulley and accessory
pulley.
• Tighten 2 bolts.
9. INSTALL DRIVE BELT.

(a) Gasolin vehicle:
• Install the drive belt (ribbed belt).
• Apply a force of 98 N to middle of the drive belt and

check the deflection. Adjust the tensioner adjusting bolt if
necessary.
Deflection (Gasoline vehicle): ≤ 5 mm
WARNING
Be sure to make sure the egnine is stopped before
performing this operation.
• Tighten the retaining bolt to the tensioner.
• Position the upstream oxygen sensor wire harness prop-

erly.
• Tighten the upstream oxygen sensor bracket retaining

bolt.
52
(b) Diesel vehicle:

• Install 2 drive belts (V-belt).
52
• Apply a force of 98 N to middle of the drive belt and

check the deflection. Adjust the power steering pump
pulley adjusting bolt if necessary.
Deflection (Diesel vehicle)： 5.5 ～ 8.5 mm
WARNING
Make sure the egnine is stopped before performing this
operation.
• Tighten 2 power steering pump retaining bolts.
10. CONNECT POWER STEERING LINE ASSY TO FLUID

RESERVIOR.
• Coat the sealant on the high-pressure tube connector.
• Connect the high-pressure tube to power steering pump.
CAUTION
• Connect the low-pressure hose to fluid reservior and

tighten the clamp.
CAUTION

CAUTION
tighten the clamp.
CAUTION
11. INSTALL AIR INTAKE DUCT.

(a) Install the air intake duct and tighten 2 bolts.
12. INSTALL ENGINE COVER.

(a) Install the engine cover and tighten 4 bolts.
13. FILL FLUID. (Refer to “Chapter 52 power steering - steering fluid,replacement”)

POWER STEERING - POWER STEERING LINE ASSY 52-27
POWER STEERING LINE ASSY

REPLACEMENT
1. PRECAUTION. (Refer to “Chapter 52 power steering - power steering system, precaution”) 52
3. REMOVE POWER STEERING LINE ASSY.

(a) Loosen 2 power steering line assy retaining bolts.
NOTE
Loosen the 2 bolts on gasoline vehicles by the same
procedures as diesel vehicles, although the two power
steering lines look different.
52
(b) Separate the power steering line assy from the power
steering pump and the steering fluid reservior.
Gasoline vehicles:
pump.
CAUTION
CAUTION
Diesel vehicles:
pump.
CAUTION
CAUTION
(c) Separate the power steering line assy from the steering
gear assy.
• Separate the high-pressure tube from the steering gear
assy.
CAUTION
from the steering gear assy.
CAUTION
52-28 POWER STEERING - POWER STEERING LINE ASSY
(d) Remove the power steering line assy.

(e) Loosen 3 bolts to separate the high-pressure line assy from the low-pressure line assy.
NOTE
Separate the high-pressure line assy from the low-pressure line assy on gasoline vehicles by the same
procedures as diesel vehicles, although these two lines look different.
4. INSTALL POWER STEERING LINE ASSY.

(a) Tighten 3 bolts attaching the hig-pressure line assy to the low-pressure line assy.
NOTE
Connect the power steering line assy on gasoline vehicles by the same procedures as diesel vehicles,
although these two lines look different.
(b) Position the power steering line assy properly.
(c) Connect the power steering line assy to the power steer-
ing pump and the steering fluid reservior.
Gasoline vehicles:

CAUTION
tighten the clamp.
CAUTION
Diesel vehicles:

CAUTION
tighten the clamp.
CAUTION
(d) Connect the power steering line assy to the steering gear
assy.
POWER STEERING - POWER STEERING LINE ASSY 52-29
• Connect the hig-pressure tube to the steering gear assy.

CAUTION
52
• Connect the low-pressure hose to the steering gear assy
CAUTION
(e) Tighten 2 bolts attaching power steering line assy to

power steering line assy.
NOTE
Tighten the 2 bolts on gasoline vehicles by the same
procedures as diesel vehicles, although the two power 52
5. FILL FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”)

52-30 POWER STEERING - STEERING GEAR ASSY
STEERING GEAR ASSY

OVERHAUL
CAUTION
Do not disassemble the power steering pump because of its high precision.
3. TURN STEERING WHEEL STRAIGHTLY.

tires to straight ahead.
4. SEPARATE STEERING TIE ROD FROM STEERING

KNUCKLE.
(a) Separate the steering tie rod LH from the steering
knuckle arm LH.
• Remove the cotter pin.
WARNING
Do not reuse the removed cotter pin.
• Loosen the slotted nut.
• Set the steering tie rod LH aside.
(b) Separate the steering tie rod RH from the steering

knuckle RH.
POWER STEERING - STEERING GEAR ASSY 52-31
NOTE
Separate the RH side by the same procedures as the LH
side.
52
5. SEPARATE POWER STEERING LINE ASSY FROM
STEERING GEAR ASSY.
(a) Separate the high-pressure tube from the steering gear
assy.
CAUTION
(b) Loosen the clamp and separate the low-pressure hose
from the steering gear assy.
CAUTION
52
(c) Loosen 2 retaining bolts from power steering line assy.
NOTE
Loosen the 2 bolts on gasoline vehicles by the same
6. SEPARATE STEERING PROPELLER SHAFT FROM

STEERING GEAR ASSY.
(a) Mark on the steering propeller shaft and the steering
gear assy.
CAUTION

(c) Pull the steering propeller shaft up from the steering gear
assy.
7. REMOVE STEERING GEAR ASSY.

(a) Loosen 4 bolts.
(b) Remove the steering gear assy.

WARNING
Take care because the steering gear assy is quite heavy.
8. INSPECT STEERING GEAR ASSY.

(a) Check the steering gear assy for crack by magnetic testing.
If any fault is found, replace with a new steering gear assy.
(b) Check the contact area between steering tie rod B-joint
and steering knuckle arm.
• Apply red lead evenly to the steering tie rod B-joint shaft
and hole of steering knuckle arm.
• Insert the steering tie rod B-joint shaft into the hole of
steeering knuckle arm, then pull it out again. Check the
contact area.
Standard: red area ≤ 3/4 shaft length, evenly
If any problem is found, replace with a new steering gear assy and
steering knuckle arm. (Refer to “Chapter 52 power steering -
steering gear assy, overhaul”, “Chapter 34 axle and propeller shaft -
steering knuckle, overhaul”)
9. INSTALL STEERING GEAR ASSY.

(a) Position the steering gear assy properly.
WARNING
Take care because the steering gear assy is quite heavy.
52
(b) Tighten 4 bolts.

Torque: 118 ± 10 N·m
52
10. CONNECT STEERING PROPELLER SHAFT TO

STEERING GEAR ASSY.
(a) Install the steering propeller shaft to the steering gear
CAUTION
(b) Tighten the bolt.

11. CONNECT POWER STEERING LINE ASSY TO STEERING GEAR ASSY.

(a) Coat the sealant on the high-pressure tube connector.
(b) Connect the high-pressure tube to steering gear assy.

CAUTION
(c) Connect the low-pressure hose to steering gear assy
CAUTION
(d) Tighten 2 bolts attaching power steering line assy to the

steering gear assy.
NOTE
Tighten the 2 bolts on gasoline vehicles by the same
12. CONNECT STEERING TIE ROD TO STEERING

KNUCKLE.
(a) Connect the steering tie rod LH to the steering knuckle LH.
• Insert the steering tie rod LH B-joint shaft into the
steering knuckle arm LH hole.
• Tighten the slotted nut.

• Install the cotter pin.

WARNING
Be sure to use a new cotter pin.
(b) Connect the steering tie rod RH to the steering knuckle arm RH.
NOTE
Connect the RH side by the same procedures as the LH side. 52
13. FILL FLUID. (Refer to “Chapter 52 power steering - power steering system, replacement”)
14. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT. (Refer to “Chapter 31 front suspension -
front wheel alignment, adjustment”)
52
52-36 POWER STEERING - STEERING FLUID RESERVIOR
STEERING FLUID RESERVIOR

REPLACEMENT
CAUTION
Generally, handling the power steering pump with fluid reservior assy as a whole. Do not separate the
fluid reservior from the power steering pump unless for special reasons.
3. SEPARATE LOW-PRESSURE HOSE FROM STEERING

FLUID RESERVIOR.
Loosen the clamp and separate the low-pressure hose from
the steering fluid reservior.
CAUTION

Loosen the clamp and separate the low-pressure hose from
the steering fluid reservior.
CAUTION
4. REMOVE STEERING FLUID RESERVIOR.

(a) Gasolin vehicles:
• Disconnect 2 connectors.
• Remove the steering fluid reservior.

POWER STEERING - STEERING FLUID RESERVIOR 52-37
NOTE
Remove the steering fluid reservior on gasoline vehicles by
the similar procedures as diesel vehicles, although the two
power steering lines look different. 52
5. INSTALL STEERING FLUID RESERVIOR.

• Position the steering fluid reservior properly.
• Connect 2 connectors. 52

NOTE
Install the steering fluid reservior on gasoline vehicles by
the similar procedures as diesel vehicles, although the two
power steering lines look different.
6. CONNECT LOW-PRESSURE HOSE TO STEERING

FLUID RESERVIOR.
Connect the low-pressure hose to steering fluid reservior
CAUTION
52-38 POWER STEERING - STEERING FLUID RESERVIOR

Connect the low-pressure hose to steering fluid reservior
CAUTION
7. FILL FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”)

HEATER AND AIR CONDITIONING
61
HEATER AND AIR CONDITIONING.................................................. 61-1
PRECAUTION.............................................................................. 61-1
ON-VEHICLE INSPECTION ........................................................ 61-8 61
VENT DUCT ....................................................................................... 61-9
REPLACEMENT .......................................................................... 61-9
HEATER PIPE .................................................................................. 61-10
COMPONENTS ......................................................................... 61-10 61
REPLACEMENT ........................................................................ 61-12
FRONT HEATER ASSY ................................................................... 61-16 61
COMPONENTS ......................................................................... 61-16
REPLACEMENT ........................................................................ 61-17
REAR HEATER ASSY ..................................................................... 61-26
COMPONENTS ......................................................................... 61-26
REPLACEMENT ........................................................................ 61-27
REFRIGERANT ................................................................................ 61-30
ON-VEHICLE INSPECTION ...................................................... 61-30
REPLACEMENT ........................................................................ 61-36
COMPRESSOR OIL ......................................................................... 61-39
INSPECTION ............................................................................. 61-39
REPLACEMENT ........................................................................ 61-40
A/C PIPE .......................................................................................... 61-41
COMPONENTS ......................................................................... 61-41
REPLACEMENT ........................................................................ 61-42
FRONT EVAPORATOR ASSY ........................................................ 61-51
COMPONENTS ......................................................................... 61-51
OVERHAUL ............................................................................... 61-52
REAR EVAPORATOR ASSY........................................................... 61-61
REPLACEMENT ........................................................................ 61-62
COMPRESSOR ................................................................................ 61-66
COMPONENTS ......................................................................... 61-66
OVERHAUL ............................................................................... 61-67
FRONT BLOWER............................................................................. 61-71
REPLACEMENT ........................................................................ 61-71
REAR BLOWER............................................................................... 61-72
REPLACEMENT ........................................................................ 61-72
CONDENSER ................................................................................... 61-74
COMPONENTS ......................................................................... 61-74
ON-VEHICLE INSPECTION ...................................................... 61-75
OVERHAUL ............................................................................... 61-76
ACCUMULATOR.............................................................................. 61-80
COMPONENTS ......................................................................... 61-80
REPLACEMENT ........................................................................ 61-81
A/C CONTROLLER.......................................................................... 61-83
COMPONENTS ......................................................................... 61-83
REPLACEMENT ........................................................................ 61-84
HEATER AND AIR CONDITIONING - HEATER AND AIR CONDITIONING 61-1

PRECAUTION
1. IGNITION SWITCH. 61
Position Description
LOCK Ignition switch off
ACC Ignition switch acc
ON Ignition switch on
START Start engine
2. POWER OFF. 61
(a) Before removing or installing any electrical devices, please disconnect the negative cable to prevent
damage to the device or personal injury.
NOTE
For the vehicle equipped with the power door locks, before disconnecting the negative battery cable,
do not leave the key in the vehicle and avoid the door to be locked.
(b) Make sure ignition switch is OFF if no specific instructions.
3. WHEN DISCONNECTING NEGATIVE BATTERY CABLE, CLOCK IN INSTRUMENT CLUSTER IS
CLEAR.
NOTE
The total odometer is not clear.
4. WHEN DISCONNECTING NEGATIVE BATTERY CABLE, MEMORY OF THE AUDIO SYSTEM WILL
BE ERASED.
NOTE
When work is finished, reset the audio systems as they were before. (Refer to “OWNER’S MANUAL”)
5. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED

AREA OR NEAR AN OPEN FLAME.
6. DO NOT DO WELDING OPERATION TO THE PARTS FILLLING OF REFRIGERANT.

7. ALWAYS WEAR EYE PROTECTION GLASSES.
61-2 HEATER AND AIR CONDITIONING - HEATER AND AIR CONDITIONING
8. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN

YOUR EYES OR ON YOUR SKIN.
If liquid refrigerant gets in your eyes or on your skin:
(a) Wash the area with cool water.
NOTE
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go to a physician or hospital immediately for profes-
sional treatment.
9. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME.
10. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT.
11. DO NOT OPERATE COMPRESSOR WITHOUT

ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM.
If there is no enough refrigerant in the refrigerant system, oil
lubrication will be insufficient and compressor will be burned out.
So take care to avoid occurring this condition.
12. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE
WHILE COMPRESSOR IS OPERATING.
If the high pressure valves opened, refrigerant flows in the
reverse direction and could cause the charging cylinder to
rupture. So only open and close the lower pressure valve.
13. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT.

If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine
overheating, etc.
14. OTHER NOTICES:
(a) When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
(b) When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before
connecting the components. connect all refrigerant loop components as quickly as possible to minimize
the entry of moisture into the system.
(c) Only use the specified compressor oil from a sealed container. immediatedly reseal containers of
compressor oil. without proper sealing, compressor oil will become moisture saturated and should not
be used.
(d) Avoid breathing a/c refrigerant and compressor oil vapor or mist. exposure may irritate eyes, nose and
throat. remove r-134a from the a/c system using certified service equipment meeting requirements of r-
134a recycling equipment, or r-134a recycling equipment. if accidental system discharge occurs,
ventilate work area before resuming service. additional health and safety information may be obtained
from refrigerant and compressor oil manufacturers.
(e) Do not allow compressor oil to come in contact with styrofoam parts. damage may occurred.
(f) Do not store or heat refrigerant containers above 52°c.
(g) Do not intentionally drop, puncture, or incinerate refrigerant containers.
(h) Do not pressure test or leak test r-134a service equipment and/or vehicle air conditioning systems with
compressed air during repairing. some mixtures of air and r-134a have been shown to be combustible
at elevated pressures. these mixtures, if ignited, may cause injury or property damage. additional
health and safety information may be obtained from refrigerant manufacturers.

cause of the problem. Check each part in order. If necessary, replace these parts.
1. COOLING SYSTEM DOES NOT FUNCTION. 61
1. Fuse (Burned) -
2. Belt (Loose) -
3. A/C clutch (Damaged) -
4. A/C cut relay (Damaged) -
Chapter 61 heater and air conditioning 61

5. A/C switch (Damaged) - A/C controller, replacemrnt
6. Dual function pressure switch Chapter 61 heater and air conditioning

(Damaged) - accumulator, replacement
Air flow is normal,
compressor does not work
7. In-vehicle temperature sensor Chapter 61 heater and air conditioning
(Damaged) - front evaporator, replacement
8. A/C clutch relay (Damaged) -
9. A/C relay (Damaged) -
10.ECM (Damaged) -
11. Harness (Open or short) -
Chapter 61 heater and air conditioning

12.Compressor (Damaged) - compressor, replacement
1. Fuse (Damaged) -
2. Harness (Open or short) -

3. Blower switch (Damaged) - A/C controller, replacemrnt
Blower is inoperative
4. Blower resistor (Damaged) - blower, replacement

5. Blower (Damaged) - blower, replacement

1. Refrigerant (Leakage) - Refrigerant, on-vehicle inspection
Cooling insufficient (air flow Chapter 61 heater and air conditioning

normal, compressor work) 2. Compressor (Damaged) - compressor, replacement

3. Accumulator (Blockage) - accumulator, replacement
2. COOLING SPORADIC
1. Harness (Poor contact) -
2. Relay (Poor contact) -
Chapter 61 heater and air

3. Blower switch (Damaged) conditioning - A/C controller,
replacemrnt
Air flow sporadic Chapter 61 heater and air
4. Blower resistor (Damaged) conditioning - blower, replacement

5. Blower (Inner poor contact) conditioning - blower, replacement

6. Vent duct (Blockage) conditioning - vent duct,
replacement
1. Belt (Slipping) -
2. A/C clutch (Slipping) -

3. A/C switch (Damaged) conditioning - A/C controller,
replacemrnt

4. Dual function pressure switch conditioning - accumulator,
Compressor work sporadic (Damaged) replacement

5. In-vehicle temperature sensor conditioning - front evaporator,
(Damaged) replacement

6. Compressor (Damaged) conditioning - compressor,
replacement

1. In-vehicle temperature sensor conditioning - front evaporator,
Blower and compressor normal, but (Loose) replacement
cooling sporadic
2. System block intermittently -
3. COOLING INSUFFICIENT
1. Harness (Poor contact) - 61
2. Relay (Poor contact) -

3. Blower switch (Damaged) conditioning - A/C controller,
replacemrnt
Air abnormal Chapter 61 heater and air
4. Blower resistor (Damaged) conditioning - blower, replacement

5. Blower (Inner poor contact) conditioning - blower, replacement
61
6. Vent duct (Blockage) conditioning - vent duct,
replacement
1. A/C clutch (Slipping) -
2. Belt (Slipping) -

Air flow normal, compressor
abnormal
replacement

5. Accumulator (Blockage) conditioning - accumulator,
replacement

1. Refrigerant (Leakage) conditioning - Refrigerant, on-
vehicle inspection

Pressure low on both low and high
2. Accumulator (Utter blockage) conditioning - accumulator,
pressure sides
replacement

3. Condenser (Frosting) conditioning - Refrigerant, on-
vehicle inspection

1. Refrigerant (Redundancy) conditioning - Refrigerant, on-
vehicle inspection

Pressure high on both low and high 2. Air mixed in refrigerant system conditioning - Refrigerant, on-
pressure sides vehicle inspection
3. Condenser (Surface filth -

blockage)
4. Expansion valve (filth blockage) -
Pressuer too high on low pressure Chapter 61 heater and air

side, Pressure too low on high 1. Compressor (Damaged) conditioning - compressor,
pressure side replacement

1. Accumulator (Inlet or inner conditioning - accumulator,
blockage) replacement
Pressuer too high on high pressure Chapter 61 heater and air

side, Pressure too low on low 2. Condenser (Blockage) conditioning - condenser,
pressure side replacement

3. Compressor - accumulator conditioning - A/C pipe,
pipeline (Blockage) replacement

1. Temperature control switch conditioning - A/C controller,
(Damaged) replacemrnt
Others
2. Blend door (Damaged) conditioning - front evaporator,
replacement
4. COOLING SYSTEM BIG NOISE
1. Belt (Loose) -
2. Compressor bracket (Damaged) -

replacement

System outer noise 4. Compressor oil (Less than conditioning - compressor oil,
specification) replacement

5. A/C clutch (Slipping) conditioning - compressor,
replacement

6. Blower (Damaged) conditioning - blower, replacement

1. Refrigerant (Incorrect) conditioning - Refrigerant, on-
vehicle inspection

2. Air mixed in refrigerant system conditioning - Refrigerant, on-
System inner noise
(Slipping) vehicle inspection
3. Pressuer too high on high Chapter 61 heater and air

pressure side (Compressor conditioning - Refrigerant, on-
abnormal) vehicle inspection
5. NO HEATING OR HEATING INSUFFICIENT

Chapter 61 heater and air 61
1. Blower (Damaged) conditioning - blower, replacement

2. Blower relay (Damaged) conditioning - blower, replacement

3. Vent duct (Shedding) conditioning - vent duct,
No heating replacement

4. Blend door (Damaged) conditioning - front evaporator,
replacement
61
5. A/C controller (Manual A/C) conditioning - A/C controller,
(Cable shedding) replacemrnt
1. Coolant (Insufficient) -

2. Heater core (Deformation) conditioning - front heater,
Heating insufficient replacemrnt

3. Heater hose (Fouling or air in conditioning - heater hose,
hose) replacemrnt
1. COMPRESSOR ASSY WITH CLUTCH
(a) Connect the positive pole from the battery to cable and negative lead to the body ground.
(b) Check the clutch energized or not.
If operation is not as specified, replace the compressor assy.
2. HEATER CORE
Add coolant to heater core and then check for leakage.
3. A/C PIPE
Water immersion: With dry nitrogen pipe inside, high-pressure pipe is 3.5 MPa and low-pressure is 1.67 MPa.
Immerse them in the water for 5 minutes to see whether there is bubble on the surface.
4. EVAPORATOR
Water immersion: Pump 1.67 MPa pressure into the evaporator, then immerse it in the water for 5 minutes to
see whether there is bubble on the surface.
5. CONDENSER
Water immersion: Pump 3.5 MPa pressure into the condenser, then immerse it in the water for 3 minutes to
see whether there is bubble on the surface.
HEATER AND AIR CONDITIONING - VENT DUCT 61-9
VENT DUCT
REPLACEMENT
1. REMOVE INSTRUMENT PANEL. (Refer to “Chapter 83 instrument panel - dashboard, replacement”) 61
2. REMOVE VENT DUCT LH.

(a) Remove 3 screws, then remove vent duct LH.
61
3. REMOVE VENT DUCT RH.

(a) Remove 2 screws, then remove vent duct RH.
4. INSTALL VENT DUCT LH.

(a) Position the vent duct LH properly.
5. INSTALL VENT DUCT RH.

(a) Position the vent duct RH properly.
6. INSTALL INSTRUMENT PANEL. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

61-10 HEATER AND AIR CONDITIONING - HEATER PIPE
HEATER PIPE
COMPONENTS
1 Blower Assy 11 Screw
2 Nut 12 Screw
3 Front Heater Assy 13 Vent Pipe Assy
4 Combined Screw 14 Sunshine Sensor Cap
5 Bolt Front Air Heater Water-inlet Rubber Pipe

15
Bracket
Front Air Heater Dual-hole Rubber
6
Grommet Front Air Heater Water-inlet Rubber Pipe
16
Clamp
7 Clamp
17 Washer
8 Front Air Heater Water-inlet Hose
18 Washer
9 Front Air Heater Water-outlet Hose
19 Bolt
10 Screw
HEATER AND AIR CONDITIONING - HEATER PIPE 61-11
61
61
1 Clamp 11 Rear Heater Assy
2 Water-inlet Hose 1 12 Screw
3 Water-outlet Hose 1 13 Plastic Guide For Nut
4 Bolt 14 Rear Heater Cap
5 Bolt Rear Heater Water Valve And Bracket

15
Assy
6 Rear Heater Water Tube Assy I
16 Rear Heater Water Tube Assy II
7 Bolt
17 Bolt
8 Rear Heater Controller Assy
18 Hole Plug
9 Spring Clip
Rear Air Heater Dual-hole Rubber
10 Bolt 19
Grommet
REPLACEMENT
1. DRAIN COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)
2. REMOVE FRONT HEATER WATER-INLET AND

WATER OUTLET HOSES.
(a) Loosen 2 clamps, then pull out 2 hoses.
(b) Loosen the clamp attaching the front heater water-inlet

hose to the engine, then pull out the hose.
(c) Loosen the clamp attaching the front heater water-outlet

hose to the engine, then pull out the hose.
3. REMOVE REAR HEATER PIPE.

(a) Raise the vehicle.
(b) Loosen 2 clamps, then pull out the water-inlet and water-
outlet hoses.
(c) Loosen 2 clamps of the water valve, then pull out the
hoses.
61
(d) Remove 2 mounting bolts of clips.
61
(e) Remove the mounting bolt of the clip.
(f) Loosen 4 clamps, then pull out the rear heater hoses.
4. INSTALL REAR HEATER PIPE.

(a) Position the rear heater hoses properly.
(b) Tighten 4 clamps.
(c) Position the tubes properly and then Tighten the clip bolt.
(d) Position the tubes properly and then Tighten 2 clip bolts.
(e) Install 2 side hoses of the water valve, then tighten 2

clamps.
(f) Install water-inlet and water-outlet hoses and then

tighten 2 clamps.
(g) Lower the vehicle.
5. INSTALL FRONT HEATER WATER-INLET AND WATER-

OUTLET HOSES.
(a) Install 2 hoses and then tighten 2 clamps.
(b) Install the front water-inlet hoses connecting to the engine,

then tighten the clamp.
61
(c) Install the front water-outlet hoses connecting to the

engine, then tighten the clamp.
61
6. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

61-16 HEATER AND AIR CONDITIONING - FRONT HEATER ASSY
FRONT HEATER ASSY

COMPONENTS
1 Blower Assy 11 Screw
2 Nut 12 Screw
3 Front Heater Assy 13 Vent Pipe Assy
4 Combined Screw 14 Sunshine Sensor Cap
5 Bolt Front Air Heater Water-inlet Rubber Pipe

15
Bracket
Front Air Heater Dual-hole Rubber
6
Grommet Front Air Heater Water-inlet Rubber Pipe
16
Clamp
7 Clamp
17 Washer
8 Front Air Heater Water-inlet Hose
18 Washer
9 Front Air Heater Water-outlet Hose
19 Bolt
10 Screw
HEATER AND AIR CONDITIONING - FRONT HEATER ASSY 61-17
REPLACEMENT
1. REMOVE INSTRUMENT PANEL. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)
61
3. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,
replacement”)
4. REMOVE FRONT HEATER WATER-INLET AND WATER-

OUTLET HOSES.
61
5. REMOVE A/C PIPE.

(a) Remove 2 mounting nuts attaching front evaporator to
frame.
(b) Remove 2 mounting bolts attaching A/C pipes to front

evaporator, then set aside A/C pipes.
6. REMOVE AIR VENT PIPE.

(a) Remove 2 retaining screws of air vent pipe at right side.
(b) Remove the retaining screw of air vent pipe at left side.
(c) Remove air vent pipe.
7. REMOVE BLEND DOOR ACTUATOR.

(a) Disconnect the connector or cable.
• Auto A/C:
Disconnect the connector.
• Manual A/C:
Disconnect the cable.
(b) Remove 3 mounting screws.

(c) Remove blend door actuator.
8. REMOVE MODE DOOR ACTUATOR.

• Auto A/C:
• Manual A/C:
(b) Disconnect the connecting rod.

(c) Remove 3 mounting screws.

(d) Remove the mode door actuator.
61
9. DISCONNECT A/C AMPLIFIER AND IN-VEHICLE

TEMPERATURE SENSOR CONNECTORS.
61
10. REMOVE FRONT BLOWER RESISTOR.

(a) Disconnect the connector.

(c) Remove the bolwer resistor.
11. REMOVE FRONT EVAPORATOR ASSY AND HEATER

ASSY.
(a) Remove 2 upper mounting nuts, 1 mounting screw and 1
mounting bolt.
(b) Remove the left lower mounting bolt.
(c) Remove 2 lower mounting bolts.

(d) Carefully take out front evaporator assy and front heater
assy.
(e) Remove 2 screws, then separate the front heater assy

and front evaporator assy.
12. REMOVE FRONT HEATER CORE.

(a) Remove 2 screws.
(b) Take out the front heater core.
61
13. INSPECT FRONT HEATER CORE.

(a) Fill coolant to the front heater core to check for leakage.
(b) Check heater core fins for tidiness. If there are skew,
61
crushing, collapsed, repair it with fin comb.
14. INSTALL FRONT HEATER CORE.

(a) Position the front heater core properly.
15. INSTALL FRONT HEATER ASSY AND FRONT

EVAPORATOR ASSY.
(a) Tighten 2 screws to connect the front evaporator assy
and front heater assy.
(b) Position the front evaporaotr assy and front heater assy.
(c) Tighten 2 upper nuts, 1 screw and 1 bolt.
Torque: 21 ~ 25 N·m
(d) Tighten 2 lower bolts.

16. INSTALL FRONT BLOWER RESISTOR.

(a) Tighten 2 mounting screws.
(b) Connect the connector.

17. CONNECT A/C AMPLIFIER AND IN-VEHICLE

61
18. INSTALL MODE DOOR ACTUATOR.

(a) Position the mode door actuator properly.
(b) Tighten 3 mounting screws.
61
(c) Connect the connecting rod.
(d) Connect the connector or cable.

• Auto A/C:
Connect the connector.
• Manual A/C:
Connect the cable.
19. INSTALL BLEND DOOR ACTUATOR.

(a) Position the blend door actuator properly.
(c) Connect the connector or cable.

• Auto A/C:
• Manual A/C:
Connect the cable.
20. INSTALL AIR VENT PIPE.

(a) Position the air vent pipe properly.
(b) Tighten 2 retaining screws of air vent pipe at right side.
(c) Tighten the retaining screw of air vent pipe at left side.
21. INSTALL A/C PIPE.

(a) Tighten 2 mounting bolts attaching A/C pipes to front
evaporator.
(b) Tighten 2 mounting nuts attaching front evaporator to

frame.
22. INSTALL FRONT HEATER WATER-INLET AND

WATER-OUTLET HOSES.
(a) Install 2 hoses, then tighten 2 clamps.
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23. INSTALL INSTRUMENT PANEL. (Refer to “Chapter 83 instrument panel - dashboard,

replacement”)
61
25. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,
replacement”)
26. CHECK REFRIGERANT FOR LEAKAGE. (Refer to “Chapter 61 heater and air conditioning -
refrigerant, on-vehicle inspection”)
61-26 HEATER AND AIR CONDITIONING - REAR HEATER ASSY
REAR HEATER ASSY

COMPONENTS
1 Clamp 11 Rear Heater Assy
2 Water-inlet Hose 1 12 Screw
3 Water-outlet Hose 1 13 Plastic Guide
4 Bolt 14 Rear Heater Cap
5 Bolt Rear Heater Water Valve And Bracket

15
Assy
6 Rear Heater Water Tube Assy I
16 Rear Heater Water Tube Assy II
7 Bolt
17 Bolt
8 Rear Heater Controller Assy
18 Hole Plug
9 Spring Clip
Rear Air Heater Dual-hole Rubber
10 Bolt 19
Grommet
HEATER AND AIR CONDITIONING - REAR HEATER ASSY 61-27
REPLACEMENT
2. REMOVE SIDE WALL REAR LOWER GUARD BOARD LH. (Refer to “Chapter 88 exterior and
61
interior - side wall guard board, replacement”)
3. REMOVE REAR HEATER PIPE.

(a) Raise the vehicle.
(b) Loosen 2 clamps, then pull out the water-inlet and water-
outlet hoses.
61
4. REMOVE REAR HEATER ASSY.

(a) Disconnect the rear heater assy connectors.
(b) Remove 2 screws, then remove the rear heater resistor.
(c) Remove 3 screws, then remove rear heater blower.

61-28 HEATER AND AIR CONDITIONING - REAR HEATER ASSY
(d) Remove 4 bolts and 1 screw of the rear heater assy.

(e) Remove the rear heater assy.
5. INSTALL REAR HEATER ASSY.

(a) Position the rear heater assy properly.
(b) Tighten 4 bolts and 1 screw of the rear heater assy.
(c) Position rear heater resistor properly.

(d) Tighten 2 screws.
(e) Position rear heater blower.

HEATER AND AIR CONDITIONING - REAR HEATER ASSY 61-29
(g) Connect the rear heater assy connectors.
61
(h) Install water-inlet and water-outlet hoses and then

tighten 2 clamps.
61

7. INSTALL SIDE WALL REAR LOWER GUARD BOARD LH. (Refer to “Chapter 88 exterior and
interior - side wall guard board, replacement”)
61-30 HEATER AND AIR CONDITIONING - REFRIGERANT
REFRIGERANT
1. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET.
(a) This is a method in which the trouble is located by using a manifold gauge set. Read the manifold
gauge pressure when these conditions are established.
Test conditions:
• Temperature at the air inlet is 30 ~ 35 ℃
• Engine running at 1500 RPM
• Blower switch at “HI” position
• Temperature control switch at “COOL” position
• A/C switch ON
• Full open doors
NOTE
These gauge indications are shown when the refrigerant system has been opened and the refrigerant
charged without vacuum purging.
• Normally function refrigerant system.

Gauge reading:
Low pressure side: 0.15 ~ 0.25 MPa
High pressure side: 1.37 ~ 2.37 MPa
• Moisture present in refrigerant system (Condition: Peri-

odically cools and then fails to cool)
Symptom Probable Cause Diagnosis Remedy

During operation, Moisture in refrigerating Accumulator in 1. Replace condenser
pressure on low pressure system freezes at oversaturated state 2. Remove moisture in
side sometimes become a expansion valve orifice Moisture in refrigerating cycle by repeatedly
vacuum and sometimes causing a temporary stop system freezes at evacuating air
normal of cycle. However, when it expansion valve orifice 3. Supply proper amount
melts, normal state is and blocks circulation of of new refrigerant
restored. refrigerant.
HEATER AND AIR CONDITIONING - REFRIGERANT 61-31
• Insufficient cooling (Condition: Cooling system does not

function effectively.)
61

61
1. Check for gas leakage
and repair if necessary
2. Supply proper amount
of new refrigerant
Pressure low on both low 3. If indicated pressure
and high pressure sides Gas leakage in Insufficient refrigerant value is closed to 0
Insufficient cooling refrigeration system Refrigerant leakage when connected to
performance gauge, creat the
vacuum after
inspecting and
repairing location of
leak
• Poor circulation of refrigerant (Condition: Cooling system

does not function effectively.)

Pressure low on both low Refrigerant flow
and high pressure sides obstructed by dirt in
Accumulator clogged Replace accumulator
Frost on pipe from accumulator
condenser to unit
• Refrigerant does not circulate (Condition: Cooling

functions intermittently.)
1. Check expansion
valve
2. Clean out dirt in
Vacuum indicated on low expansion valve by air
pressure side, very low Refrigerant flow blowing
pressure indicated on obstructed by moisture or
high pressure side dirt in refrigerant system 3. Replace condenser
Refrigerant not circulate 4. Evacuate air and
Frost or drew seen on refrigerant flow obstructed
pipe befroe and after by gas leaked from supply proper amount
accumulator or expansion expansion valve of new refrigerants
valve 5. For gas leakage from
expansion valve,
replace expansion
valve
• Refrigerant overcharged or insufficient cooling of

condenser (Condition: Cooling system does not function
effectively.)
1. Clean condenser
Unable to develop Excessive refrigerant in 2. Check cooling fan with
sufficient performance cycle cooling fan motor
Pressure too high on both
due to excessive use of Condnser cooling operation
low and high pressure
refrigeration system insufficient condenser 3. If 1 and 2 are in normal
sides
Insufficient cooling of fins state, check refrigerant
condenser Clogged at cooling fan and supply proper
amount of refrigerant.
• Air present in refrigeration system (Condition: Cooling

system does not function.)
61

61
Pressure too high on both 1. Check compressor oil
low and high pressure Air present in refrigeration
to see if it is dirty or
sides Air entered in refrigeration system
insufficient
The low pressure pipe system Insufficient vacuum
purging 2. Vacuumize and supply
overheated new refrigerant
• Expansion valve trouble (Condition: Refrigerant functions

insufficient.)

Pressure too high on both
low and high pressure Excessive refrigerant in
sides Trouble in expansion low pressure pipe Check and replace
Frost or large amount of valve Expansion valve opened expansion valve
dew on pipe of low too wide
presside side
• Compressor failure (Condition: Refrigerant is not

effective.)

Pressure too high on low Compressor failure
pressure side Internal leakage in Leakage from damaged Repair or replace
Pressure too low on high compressor valve or broken sliding compressor
pressure side parts
Gauge reading (Reference)
1 Blower LO Zone 2 Blower HI Zone
2. LEAKAGE DETECTION WITH SOAP SOLUTION.

(a) For a large amount of leakage on refrigerant pipe connection, leakage can be detected by spraying
soap liquid around the connection with a sprayer to check whether any bubble appears. This is a simple
and convenient method for leakage detection, but it is unable to detect minor leakage.
3. LEAKAGE DETECTION WITH NON-SELECTIVE DETECTOR.

(a) This detector can detect leakage of all kinds of liquid and gas regardless of chemical composition of the
detected material. It has advantages of easy use, stable performance and low cost, etc., but it cannot
be used for area detection of leakage. 61
4. LEAKAGE DETECTION WITH HALOGEN LEAKAGE DETECTOR.
(a) It equipped with special sensor which can detect air compounds containing a small amount of fluorine,
chlorine, bromine and iodine without interference of other material. The great advantage of this
instrument is its high sensitivity which can reduce error. Its minimum detection limit is less than 5g per
year for area detection of leakage and 1.5g per year for leak-point detection (for leak-point, which leaks
1.5g per year).
5. LEAKAGE DETECTION WITH SPECIAL ELECTRONIC LEAKAGE DETECTOR.
(a) This instrument is complicated and expensive which can detect certain compounds without interference
of other material. R-134a, a kind of special electronic leakage detector with high sensitivity and
61
selectivity, can not only detect leak point correctly, but can identify whether refrigerant is R-134a type.
Because it has high sensitivity, pay attention to pollution around the instrument when using it,
otherwise, it may cause error report.
6. LEAKAGE DETECTION WITH FLUORESCENT DYE.
(a) Fluorescent dye can produce fluorescence under the irradiation of ultraviolet light. Therefore, if add this
kind of dye to compressor oil or refrigerant, the leak point can be detected through irradiating outer part
of the system when the system has a leakage.
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM.
(a) Turn the A/C switch ON.
(b) Operate the compressor at the engine RPM 1000 for 5 to 6 minutes to circulate the refrigerant and
collect compressor oil remaining in each component into the compressor as many as possible.
(c) Stop the engine.
(d) Recover the refrigerant.

NOTE
Do not release the refrigerant into the air.
2. PUMP VACUUM.
(a) Connect high pressure and low pressure gauge hoses to
maintenance valve on compressor, and connect central
hose to vacuum pump.
(b) Open high and low pressure valves of manifold pressure
gauge, and then open the vacuum pump valve.
(c) Start the vacuum pump. Keep vacuumizing for at least 20
minutes to make vacuum reading below -760 mmHg.
Shut manual valves at both high and low pressure sides
and stop vacuumizing to detect leakage.
3. INSPECT LEAKAGE OF REFRIGERANT.

(a) Shut valves, the gauge reading shall not increase within 5 minutes. If the reading increases, repair
where leaks, then pump vacuum again.
4. SUPPLY REFRIGERANT.
(a) If there is no leakage, connect central filling hose of manifold pressure gauge with refrigerant tank.
(b) Loosen the nut of manifold pressure gauge central hose, and retighten it until white gas refrigerant
flows out and a “fizz” sound is heard, which indicates that air in central hose is exhausted.
61
(c) Open high pressure manual valve, and turn refrigerant
tank upside down to fill liquid refrigerant into refrigeration
system. Do not start air conditioning system at this
moment to avoid back flow. Add at least 200g of
refrigerant each time.
61
(d) Shut high pressure manual valve and open low pressure
manual valve to allow gas refrigerant to enter
refrigeration system. Start the engine. The refrigerant
enters from low pressure manual valve must be gasified,
for liquid refrigerant will cause liquid impact in
compressor and damage the unit.
(e) Please add refrigerant according to the specified amount of the A/C system. If there is no specified
amount, observe the high and low pressure gauges and the peephole of the refrigerant flow state
(clear, sparkling, turbidity) to estimate the adding time.
Specified value:
Front and rear A/C：1250 + 0/- 25 g
Front A/C：850 ± 25 g
When estimating refrigerant adding amount, set the basic conditions:
• Radiator water temperature: maintain stable state
• A/C switch: ON
• Temperature regulator: adjust inner circulation air temperature to 25 ~ 30 ℃
• Fan swtich: HI position
• Change inner and outer air: Inner circulation
• Door: full open
• Window: full open
• Estimate the adding amount
(f) After finish the adding process, turn the HVAC switch to OFF and wait to balance pressure condition,
reopen the A/C switch to ON and begin to judge.
Sparkling condition: gas and liquid refrigerant mixed state with bubble.
Clear conditon: it is clear condition when all refrigerant is liquid.
Turbidity condition: when the oil and refrigerant are sperating state, it shows thin ivory.
Sparkling and turbidity condition: gas refrigerant and sperated oil mixing state, it shows thin ivory and
sparkling
Peephole Condition (After

Refrigerant Adding Amount Turn On The HVAC Switch High Side Pressure
About 1 Minute )
Suitable 1.8 ~ 2.5 MPa
Excessive > 2.5 MPa
Insufficient 1.2 MPa
(g) Above peephole conditions are visible general condition. When sometimes it is hard to judge the
peephole condition due to the reasons such as external condition, it must confirm to inspect the
pressure variation of the high pressure side (excessive adding when pressure sharply up).
(h) When adding refrigerant, pay attention to refrigerant condition variation in peephole and high side
pressure variation in the pressure gauge, then proceed to readding.
(i) Shut low pressure manual valve and remove maintenance valve, then cap the valve quickly to avoid
gas leakage.
5. WARM UP ENGINE.
6. INSPECT LEAKAGE OF REFRIGERANT. （Refer to “Chapter 61 heater and air conditioning -
HEATER AND AIR CONDITIONING - COMPRESSOR OIL 61-39
COMPRESSOR OIL
INSPECTION
1. Correlation method: Take fresh compressor oil into test tube as the standard oil and also take 61
old compressor oil into test tube, then compare the two tubes. If the color of the old compressor
oil is light yellow or orange, it can be used. If it turns to bronzing turbid liquid, it can not be
used.
2. Paper method: Drip a drop of compressor oil on a clean white paper, after a while check the
color of the oil. If the color is light and uniform, that shows it is no impurity and can be used. If
the center of the oil has black spot, that shows the oil is metamorphous and can not be used.
61
61-40 HEATER AND AIR CONDITIONING - COMPRESSOR OIL
REPLACEMENT
replacement”)
2. DISCHARGE COMPRESSOR OIL.
(a) Remove the compressor. (Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”)
(b) Pour out the oil from the compressor.
3. FILL COMPRESSOR OIL.
(a) Install the compressor. (Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”)
(b) Pour the oil into the compressor as the specified value.
Specified value: 180 ml
• Generally, it is no need to add oil to new A/C system, because new compressor has the whole amount
of the oil for the system (14% ~ 18% amount of the refrigerant ). If the A/C system has more than two
times repairment or other causes the lack of compressor oil, it is need to add compressor oil. After
replace the A/C system, add a given amount of the compressor oil.
Part Name Amount of oil

Compressor -
Evaporator 10 ml
Accumulator 5 ~ 10 ml
No leakage 5 ml
Condenser
Leakage 10 ml
No leakage -
Pipe
Leakage 5 ml
No leakage -
Gas leakage
Leakage 80 ml
Replace all pipes 40 ~ 60 ml

replacement”)
5. WARM UP ENGINE.
HEATER AND AIR CONDITIONING - A/C PIPE 61-41
A/C PIPE
COMPONENTS
61
61
Compressor - Front And Rear Evaporator 6 Accumulator - Rear Evaporator Pipe Assy 1
1
Pipe Assy
7 Hexagon Flange Nut
2 Bolt
8 Condenser Assy
3 Accumulator Assy
9 Compressor - Condenser Pipe Assy
4 Accumulator - Front Evaporator Pipe Assy
10 Low-pressure Pipe Assy
5 Condenser - Accumulator Pipe Assy
61-42 HEATER AND AIR CONDITIONING - A/C PIPE
REPLACEMENT
replacement”)
2. REMOVE FRONT A/C PIPES.

(a) Disconnect the connector and remove the pressure
switch.
(b) Remove 2 mounting bolts of condenser - accumulator

and accumulator - evaporator pipes.
(c) Remove accumulator - rear evaporator pipe retaining

nut.
(d) Remove 2 mounting bolts attaching accumulator - front

evaporator and low-pressure pipes to front evaporator.
(e) Remove 2 nuts attaching the pipes to the compressor

and O-ring.
61
3. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bump assy,
replacement”)
4. REMOVE A/C PIPES ON CONDENSER. 61

(a) Remove compressor - condenser pipe assy retaining
bolt.
(b) Remove condenser - accumulator pipe assy retaining

bolt.
(c) Remove 2 clamp bolts of compressor - condenser pipe

assy.
5. REMOVE REAR A/C PIPES.

(a) Remove 2 nuts of A/C pipes leading to rear evaporator.
(b) Remove front fender lining RH.

(c) Remove A/C pipe clamp bolts, then remove the clamps.
(d) Remove roof guard board assy. (Refer to “Chapter 88
exterior and interior trim - roof guard board assy,
replacement”)
(e) Remove 2 nuts attaching the A/C pipes to the rear

evaporator assy.
(f) Remove B pillar upper and lower inner guard board.

(Refer to “Chapter 88 exterior and interior trim - side wall
guard board, replacement”)
(g) Remove the carpet. (Refer to “Chapter 88 exterior and
interior trim - carpet assy, replacement”)
(h) Remove 5 bolts of the A/C pipe clamps, then remove 5

clamps.
61
61
(i) Remove 5 bolts of rear A/C cover and remove the rear A/C
cover.
(j) Raise the vehicle.
(k) Remove 3 connecting nuts of rear evaporator A/C pipes.

(l) Remove 2 nuts attaching the A/C pipes to rear

evaporator solenoid.
6. CAREFULLY TAKE OUT ALL A/C PIPES.
7. INSTALL REAR A/C PIPES.

(a) Tighten 2 nuts attaching the A/C pipes to rear evaporator
solenoid.
Torque: 12 ~ 15 N·m （Φ9）
Torque: 20 ~ 26 N·m （Φ12）
Torque: 30 ~ 35 N·m （Φ16）
(b) Tighten 3 connecting nuts of rear evaporator A/C pipes.

Torque: 12 ~ 15 N·m （Φ9）
Torque: 20 ~ 26 N·m （Φ12）
Torque: 30 ~ 35 N·m （Φ16）
(c) Position 5 A/C pipe clamps properly and then Tighten 5

bolts.
61
61
(d) Position the rear A/C cover properly and then Tighten 5
bolts.
(e) Tighten 2 nuts attaching the A/C pipes to the rear

evaporator assy.
Torque: 12 ~ 15 N·m （Φ9）
Torque: 20 ~ 26 N·m （Φ12）
Torque: 30 ~ 35 N·m （Φ16）
(f) Lower the vehicle.

(g) Tighten 2 nuts of A/C pipes leading to rear evaporator.

Torque: 12 ~ 15 N·m （Φ9）
Torque: 20 ~ 26 N·m （Φ12）
Torque: 30 ~ 35 N·m （Φ16）
8. INSTALL A/C PIPES ON CONDENSER.

(a) Tighten compressor - condenser pipe assy bolt.
(b) Tighten condenser - accumulator pipe assy bolt.
(c) Tighten 2 bolts of compressor - condenser - pipe assy

clamp.
9. INSTALL FRONT A/C PIPES.

(a) Tighten 2 nuts attaching the pipes to the compressor and
O-ring.
(b) Tighten accumulator - rear evaporator pipe retaining nut.

Torque: 12 ~ 15 N·m （Φ9）
Torque: 20 ~ 26 N·m （Φ12）
Torque: 30 ~ 35 N·m （Φ16） 61
(c) Tighten 2 mounting bolts of condenser - accumulator and

accumulator - evaporator pipes.
61
(d) Install the pressure switch and connect the connector.
(e) Tighten 2 mounting bolts attaching accumulator - front

evaporator and low-pressure pipes to front evaporator.
replacement”)
11. WARM UP THE ENGINE.
13. INSTALL B PILLAR UPPER AND LOWER INNER GUARD BOARD. (Refer to “Chapter 88 exterior
and interior trim - side wall guard board, replacement”)
14. INSTALL CARPET. (Refer to “Chapter 88 exterior and interior trim - carpet assy, replacement”)
15. INSTALL FRONT FENDER LINING RH.
16. TIGHTEN BOLTS TO A/C PIPE CLAMPS.

17. INSTALL ROOF GUARD BOARD ASSY. (Refer to “Chapter 88 exterior and interior trim - roof
guard board assy, replacement”)
HEATER AND AIR CONDITIONING - FRONT EVAPORATOR ASSY 61-51
FRONT EVAPORATOR ASSY

COMPONENTS
61
61
1 A/C Amplifier And Bracket Assy 7 Washer
2 Screw 8 Nut
3 Bolt 9 Bolt
4 Front Evaporator Assy 10 Front Evaporator Drip Pipe Assy
5 Bolt 11 Screw
6 Screw
61-52 HEATER AND AIR CONDITIONING - FRONT EVAPORATOR ASSY
OVERHAUL
1. REMOVE INSTRUMENT PANEL. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)
replacement”)
4. REMOVE FRONT HEATER WATER-INLET AND WATER-

OUTLET HOSES.
5. REMOVE A/C PIPE.

(a) Remove 2 mounting nuts attaching front evaporator to
frame.
(b) Remove 2 mounting bolts attaching A/C pipes to front

evaporator, then set aside A/C pipes.
6. REMOVE AIR VENT PIPE.

(a) Remove 2 retaining screws of air vent pipe at right side.
(b) Remove the retaining screw of air vent pipe at left side.
(c) Remove air vent pipe.
61
7. REMOVE BLEND DOOR ACTUATOR.

• Auto A/C:
61
• Manual A/C:

(c) Remove blend door actuator.
8. REMOVE MODE DOOR ACTUATOR.

• Auto A/C:
• Manual A/C:
(b) Disconnect the connecting rod.


(d) Remove the mode door actuator.
9. DISCONNECT A/C AMPLIFIER AND IN-VEHICLE

10. REMOVE FRONT BLOWER RESISTOR.


(c) Remove the blower resistor.
11. REMOVE FRONT EVAPORATOR ASSY AND HEATER

ASSY.
(a) Remove upper 2 mounting nuts, 1 mounting screw and 1
mounting bolt.
(b) Remove the left lower mounting bolt.
61
61
(c) Remove lower 2 mounting bolts.

(d) Carefully take out front evaporator assy and front heater
assy.
(e) Remove 2 screws, then separate the front heater assy

and front evaporator assy.
12. REMOVE FRONT EVAPORATOR ASSY.

(a) Remove the clamp retaining screw of the evaporator
core pipes.
(b) Remove the clips and screws around the evaporator

shell, then open the evaporator shell and take out the
evaporator core.
(c) Remove the in-vehicle temperature sensor.
13. INSTALL FRONT EVAPORATOR ASSY.

(a) Install the in-vehicle temperature sensor.
(b) Position the evaporator core properly. Install the clips
and screws around the shell.
(c) Tighten the clamp retaining screw of the evaporator core

pipes.
14. INSTALL FRONT HEATER ASSY AND FRONT EVAPORATOR

ASSY.
(a) Tighten 2 screws to connect the front evaporator assy
and front heater assy.
(b) Position the front evaporator assy and front heater assy.
(c) Tighten 2 upper nuts, 1 screw and 1 bolt.
61
(d) Tighten lower 2 bolts.

61
15. INSTALL FRONT BLOWER RESISTOR.

(a) Tighten 2 mounting screws.
(b) Connect the connector.

16. CONNECT A/C AMPLIFIER AND IN-VEHICLE TEMPERATURE

SENSOR CONNECTORS.
17. INSTALL MODE DOOR ACTUATOR.

(a) Position the mode door actuator properly.
(c) Connect the connecting rod.
(d) Connect the connector or cable.

• Auto A/C:
• Manual A/C:
Connect the cable.
18. INSTALL BLEND DOOR ACTUATOR.

(a) Position the blend door actuator properly.
(c) Connect the connector or cable.

• Auto A/C:
• Manual A/C: 61
Connect the cable.
19. INSTALL AIR VENT PIPE.

(a) Position the air vent pipe properly.
(b) Tighten 2 retaining screws of air vent pipe at right side.
61
(c) Tighten the retaining screw of air vent pipe at left side.
20. INSTALL A/C PIPE.

(a) Tighten 2 mounting bolts attaching A/C pipes to front
evaporator.
(b) Tighten 2 mounting nuts attaching front evaporator to

frame.
21. INSTALL FRONT HEATER WATER-INLET AND WATER-

OUTLET HOSES.
(a) Install 2 hoses, then tighten 2 clamps.

replacement”)
23. FILL COOLANT. (Refer to “Chapter the7A cooling - coolant, replacement”)
replacement”)
HEATER AND AIR CONDITIONING - REAR EVAPORATOR ASSY 61-61
REAR EVAPORATOR ASSY

COMPONENTS
61
61
1 Nut 12 Accumulator – Rear Evaporator Pipe Assy 4
2 Bolt 13 Rear A/C Longitudinal Beam Pipeline Assy
3 Washer 14 Bolt
4 Rear Evaporator Assy 15 Plastic Tightening Belt
5 Bolt 16 High-pressure Pipe Rubber Ring
6 Clamp 9 17 Rear Evaporator Suction Pipe Assy
7 Clamp 4 18 Clamp 2
8 Rear Evaporator Exhaust Pipe Assy 19 Clamp 1
9 Clamp 3 20 Plastic Guide
10 Rear Drip Pipe B RH 21 Screw
11 Rear Drip Pipe B LH

61-62 HEATER AND AIR CONDITIONING - REAR EVAPORATOR ASSY
REPLACEMENT
replacement”)
2. REMOVE ROOF GUARD BOARD ASSY. (Refer to “Chapter 88 exterior and interior trim - roof
3. REMOVE REAR EVAPORATOR ASSY.

(a) Remove 2 connecting nuts attaching A/C pipes to rear
evaporator assy.
(b) Remove the drip pipe RH.

(c) Remove the drip pipe LH.
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61
(d) Disconnect the rear blower resistor connector.
(e) Remove 5 mounting bolts and then remove rear evapo-

rator assy.
4. INSTALL REAR EVAPORATOR ASSY.

(a) Position rear evaporator assy properly.
(b) Tighten 5 mounting bolts.
61-64 HEATER AND AIR CONDITIONING - REAR EVAPORATOR ASSY
(c) Connect the rear blower resistor connector.
(d) Install the drip pipe LH.
(e) Install the drip pipe RH.

(f) Tighten 2 connecting nuts attaching the A/C pipes to rear

evaporator assy.
Torque: 12 ~ 15 N·m （Φ9）
Torque: 20 ~ 26 N·m （Φ12） 61
Torque: 30 ~ 35 N·m （Φ16）
61
5. INSTALL ROOF GUARD BOARD ASSY. (Refer to “Chapter 88 exterior and interior trim - roof
replacement”)
61-66 HEATER AND AIR CONDITIONING - COMPRESSOR
COMPRESSOR
COMPONENTS
1 Compressor Bracket Assy 7 Washer
2 Bolt 8 Washer
3 Bolt 9 Low-pressure Pipe Assy
4 Washer 10 Compressor - Front Evaporator Pipe Assy
5 Washer 11 Compressor Assy
6 Bolt
HEATER AND AIR CONDITIONING - COMPRESSOR 61-67
OVERHAUL
replacement”)
61
2. REMOVE COMPRESSOR.
(a) Remove engine accessory belt. (Refer to “Chapter 15A engine mechanical - engine accessory belt,
overhaul”)
(b) Remove 2 nuts attaching the pipes to the compressor

and O-ring.
61
(c) Disconnect the connector.
(d) Remove 4 mounting bolts attaching the compressor to

the compressor bracket.
(e) Remove the compressor.
3. REMOVE COMPRESSOR CLUTCH.

(a) Place the compressor in vise.
(b) Using a vise pliers, hold the compressor clutch hub.

(c) Remove the bolt, compressor clutch hub and compres-
sor clutch washer.
(d) Using a snap ring pliers, remove the snap ring and com-
pressor clutch rotor.
(e) Using a snap ring pliers, remove the snap ring and com-
pressor clutch starter.
4. INSTALL COMPRESSOR CLUTCH.

(a) Follow the parts shown in the illustration to install the
compressor clutch starter.
(b) Install a new snap ring.
(c) Using a snap ring pliers, install the compressor clutch

rotor and a new snap ring with the chamfered side facing
up.
NOTE
Do not change the combination of the compressor clutch
washers used before disassembly.
HEATER AND AIR CONDITIONING - COMPRESSOR 61-69
(d) Using a vise pliers, hold the compressor clutch hub and
tighten the bolt.
61
5. INSPECT COMPRESSOR CLUTCH CLEARANCE.

(a) Connect the battery positive to the compressor clutch
connector and the negative to the ground. Turn on and
off the compressor clutch and measure the clearance. 61
Specified clearance: 0.35 ~ 0.60 mm
If the measured value is out of the specified value, remove the
compressor clutch hub and adjust it with compressor clutch
washers.
NOTE
Adjustment should not be performed out of 3 times.
6. INSPECT COMPRESSOR OIL.
(a) If replace the compressor with new one, remove the refrigerant gas from the service valve, drain the fol-
lowing amount of oil from the new compressor before installing.
Specified value:
Oil capacity inside new compressor － remaining oil amount in the removed compressor ＝ oil
amount to be removed when replacing
NOTE
• When checking the compressor oil level, observe the precautions on the compressor removal/
installation.
• Compressor oil will remain in the pipes of the vehicle. If a new compressor is installed without
removing some oil inside, the oil amount becomes too much to prevent heat exchange in the
refrigerant cycle and cause refrigerant failure.
• If the remaining oil in the removed compressor is too little in volume, check for oil leakage.
• Be sure to use the right compressor oil.
7. INSTALL COMPRESSOR ASSY.

(a) Position the compressor properly. Tighten 4 mounting
bolts.
(b) Sufficiently apply compressor to the new O-ring and fit

surface of the compressor.
(c) Position A/C pipes properly. Tighten 2 retaining nuts.
(d) Connect the connector.
8. INSTALL ENGINE ACCESSORY BELT. (Refer to “Chapter 15A engine mechanical - engine acces-
sory belt, overhaul”)
replacement”)
10. WARM UP ENGINE.
HEATER AND AIR CONDITIONING - FRONT BLOWER 61-71
FRONT BLOWER
REPLACEMENT
1. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, 61
replacement”)
2. REMOVE INSTRUMENT PANEL. (Refer to “Chapter 83 instrument panel - dashboard,
replacement”)
4. REMOVE FRONT EVAPORATOR ASSY. (Refer to “Chapter 61 heater and air conditioning - front
evaporator assy, replacement”)
5. REMOVE FRONT HEATER ASSY. (Refer to “Chapter 61 heater and air conditioning - front heater
assy, replacement”)
61
6. REMOVE FRONT BLOWER.
(b) Remove 3 retaining screws.
(c) Take out the front blower.
7. INSTALL FRONT BLOWER.

(a) Position the front blower properly.
(b) Tighten 3 retaining screws.
(c) Connect the connector.
8. INSTALL FRONT HEATER ASSY. (Refer to “Chapter 61 heater and air conditioning - front heater
9. INSTALL FRONT EVAPORATOR ASSY. (Refer to “Chapter 61 heater and air conditioning - front
replacement”)
replacement”)
61-72 HEATER AND AIR CONDITIONING - REAR BLOWER
REAR BLOWER
REPLACEMENT
replacement”)
2. REMOVE REAR EVAPORATOR ASSY. (Refer to “Chapter 61 heater and air conditioning - rear
3. REMOVE REAR BLOWER.

(b) Remove the rubber vent hose.
(c) Remove 3 retaining screws and take out the rear blower.
4. INSTALL REAR BLOWER.

(a) Position the rear blower properly. Tighten 3 retaining
screws.
HEATER AND AIR CONDITIONING - REAR BLOWER 61-73
(b) Install the rubber vent hose.
61
(c) Connect the connector.
61
5. INSTALL REAR EVAPORATOR ASSY. (Refer to “Chapter 61 heater and air conditioning - rear
replacement”)
61-74 HEATER AND AIR CONDITIONING - CONDENSER
CONDENSER
COMPONENTS
1 Condenser Assy 9 Compressor - Condenser Pipe Assy
2 Condenser Mounting Bracket LH 10 Bolt
3 Condenser Mounting Bracket RH 11 Nut
4 Nut 12 Compressor - Condenser Pipe Clamp 1
5 Bolt 13 Compressor - Condenser Pipe Bracket
6 Nut 14 Bolt
7 Clamp 15 Bolt
8 Bolt 16 Compressor - Condenser Pipe Clamp 2

HEATER AND AIR CONDITIONING - CONDENSER 61-75
1. INSPECT CONDENSER ASSY.
(a) If a fin of the condenser assy is dirty, clean it with water and dry it with compressor air.
61
NOTE
Do not damage the fin of the condenser assy.
(b) If a fin of the condenser assy is bent, use a screwdriver or plier to make it straight.
2. INSPECT CONDENSER ASSY FOR LEAKAGE OF REFRIGERANT.
(a) Using a halogen leak detector, check pipe joints for gas leakage.
(b) If gas leakage is detected in a joint, check the torque of the joint.
61
OVERHAUL
NOTE
The condenser is a heat exchanger. It has many fine vulnerable parts (especially the heat sink) in struc-
ture and material. When removing and installing, pay attention not to dropping, collision or scraping.
replacement”)
2. REMOVE FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bump assy,
replacement”)
3. REMOVE CONDENSER ASSY.

(a) Remove the compressor - condenser pipe assy retaining
bolt.
(b) Remove the condenser - accumulator pipe assy retaining

bolt.
(c) Remove 2 clamp retaining bolts of compressor - con-

denser pipe assy.
(d) Remove the bumper middle bracket lower retaining bolt.

(e) Remove the retaining bolt of the condenser mounting

bracket LH.
61
(f) Remove the retaining bolt of the condenser mounting

bracket RH.
61
(g) Carefully take out the condenser assy.
4. INSTALL CONDENSER ASSY.

(a) Position the condenser properly.
(b) Tighten the retaining bolt of the condenser mounting

bracket RH.
(c) Tighten the retaining bolt of the condenser mounting

bracket LH.
(d) Tighten the bumper middle bracket lower retaining bolt.
(e) Tighten the condenser - accumulator pipe assy retaining

bolt.
(f) Tighten the compressor - condenser pipe assy retaining

bolt.
(g) Tighten 2 clamp retaining bolts of compressor - con-

denser pipe assy.

replacement”)
6. WARM UP ENGINE.
7. CHECK REFRIGERANT FOR LEAKAGE. (Refer to “Chapter 61 heater and air conditioning - 61
8. INSTALL FRONT BUMPER. (Refer to “Chapter 88 exterior and interior trim - front bump assy,
replacement”)
61
61-80 HEATER AND AIR CONDITIONING - ACCUMULATOR
ACCUMULATOR
COMPONENTS
1 Bolt 7 Accumulator - Rear Evaporator Pipe Assy 1
2 Bolt 8 Bolt
3 Accumulator - Front Evaporator Pipe Assy 9 Accumulator Bracket Assy
4 Condenser - Accumulator Pipe Assy 10 Bolt
5 Bolt 11 Bolt
6 Accumulator Assy
HEATER AND AIR CONDITIONING - ACCUMULATOR 61-81
REPLACEMENT
replacement”)
61
2. REMOVE DUAL FUNCTION PRESSURE SWITCH.
(a) Disconnect the connector and remove the dual function
pressure switch.
61
3. REMOVE ACCUMULATOR ASSY.
(a) Remove 2 bolts of the A/C pipes.
(b) Remove 2 bolts of the accumulator bracket and remove

the accumulator assy.
4. INSTALL ACCUMULATOR ASSY.

(a) Position the accumulator properly. Tighten 2 bolts of the
accumulator bracket.
61-82 HEATER AND AIR CONDITIONING - ACCUMULATOR
(b) Tighten 2 bolts of the A/C pipes.
5. INSTALL DUAL FUNCTION PRESSURE SWITCH.

(a) Install the dual function pressure switch and connect the
connector.

replacement”)
7. WARM UP ENGINE.
HEATER AND AIR CONDITIONING - A/C CONTROLLER 61-83
A/C CONTROLLER
COMPONENTS
61
61
1 A/C Controller Assy (Auto A/C) 3 A/C Controller Assy (Manual A/C)
2 Screw
61-84 HEATER AND AIR CONDITIONING - A/C CONTROLLER
REPLACEMENT
1. REMOVE MIDDLE UPPER COVER.
(a) Using a screwdriver, pry up the middle upper cover.
(b) Remove the middle upper cover.
(c) If here install the combined display, refer to “chapter 81
communication system - combined display, replace-
ment”.
2. REMOVE MIDDLE PANEL ASSY.

(a) Using a screwdriver, pry up the middle panel assy.
(b) Disconnect the connectors.

(c) Remove the middle panel assy.
3. REMOVE FRONT A/C CONTROLLER ASSY.

(a) Remove 4 retaining screws.
HEATER AND AIR CONDITIONING - A/C CONTROLLER 61-85
(b) Turn the front A/C controller assy.

• Auto A/C:
Disconnect the connectors.
• Manual A/C: 61
Disconnect the cables.
(c) Remove the front A/C controller.
4. INSTALL FRONT A/C CONTROLLER ASSY.

(a) Connect the front A/C controller assy.
• Auto A/C:
61
Connect the connectors.
• Manual A/C:
Connect the cables.
(b) Position the front A/C controller properly.

(c) Tighten 4 retaining screws.
5. INSTALL MIDDLE PANEL ASSY.

(a) Connect the connectors.
(b) Position the front A/C controller assy properly.

(c) Slap the middle panel by hand and the clips lock into
position. Pay attention not to damaging the inner har-
ness.
61-86 HEATER AND AIR CONDITIONING - A/C CONTROLLER
6. INSTALL MIDDLE UPPER COVER ASSY.

(a) Slap the middle upper cover by hand and the clips lock
into position.
(b) If here install the combined display, refer to “Chapter 81
communication system - combined display, replace-
ment”.
SUPPLEMENTAL RESTRAINT SYSTEM
62
SUPPLEMENTAL RESTRAINT SYSTEM ......................................... 62-1
PRECAUTION.............................................................................. 62-1
SYSTEM PRINCIPLES ................................................................ 62-2
SYSTEM PERFORMANCE ......................................................... 62-3 62
HORN SWITCH ASSY ....................................................................... 62-6
REPLACEMENT .......................................................................... 62-6
DISPOSAL ................................................................................. 62-10 62
CLOCK SPRING .............................................................................. 62-14
REPLACEMENT ........................................................................ 62-14
RCM.................................................................................................. 62-17
REPLACEMENT ........................................................................ 62-17
SUPPLEMENTAL RESTRAINT SYSTEM - SUPPLEMENTAL RESTRAINT SYSTEM 62-1

PRECAUTION
WARNING 62
• Some MPX vehicles are equipped with SRS (Supplemental Restraint System), which contains a
driver airbag. Failure to carry out service operations in the correct sequence could cause the
SRS to unexpectedly deploy during servicing. It may lead to a serious accident. Furthermore, if
a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when
required. Before servicing (including removal or installation of parts, inspection or
replacement), be sure to read the following items carefully, then follow the correct procedures
described in the service manual.
• Operation must be started 90 seconds after the ignition switch is turned to the “LOCK” position 62
and the negative (-) cable and positive (+) cable are disconnected from the battery. (The SRS is
equipped with a back-up power source. If operation is started within 90 seconds after
disconnecting the battery negative (-) cable and positive (+) cable, the SRS may deploy.)
• Do not expose the horn switch assy (with driver airbag) directly to hot air or flames.
NOTE
• Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most
important source of information when troubleshooting. When troubleshooting the SRS, always
inspect the DTCs before disconnecting the battery.
• Even in case of a minor collision that the SRS does not deploy, the horn switch assy should be
inspected. (Refer to “Chapter 62 supplemental restraint system - horn switch assy, replace-
ment”, “Chapter 62 supplemental restraint system - RCM, replacement”)
• Before repairing, remove the RCM first if shocks may be applied to it during repairs.
• Never use SRS related parts from another vehicle. Be sure to replace them with new parts when
necessary.
• Do not disassemble and repair the horn switch assy.
• If the horn switch assy has been dropped, or there are cracks, dents or other faults, replace it
with a new one.
• Use a multimeter with high impedance (10 kΩ/V minimum) for troubleshooting of the SRS elec-
trical circuits.
• Information labels are attached to the SRS components. Be sure to follow the instructions on
the labels when performing operations.
• After repairing on the SRS system, perform the inspection of airbag warning light. (Refer to
“Chapter 04 diagnostics - supplemental restraint system, precheck”, “Chapter 04 diagnostics -
supplemental restraint system, SRS warning light is always on”, “Chapter 04 diagnostics -
supplemental restraint system, SRS warning light is inoperative”)
• When the negative (-) cable is disconnected from the battery, the memory of the clock and audio
system will be cleared. So before repairing, record the necessary data of the clock and audio
system. After repairing, reset the clock and audio system. Never use a back-up power supply
from another battery to avoid erasing the memory in each memory system. The back-up power
supply will supply power to the SRS system. It could cause the SRS to unexpectedly deploy
during servicing.
62-2 SUPPLEMENTAL RESTRAINT SYSTEM - SUPPLEMENTAL RESTRAINT SYSTEM
SYSTEM PRINCIPLES
1. SYSTEM STRUCTURE.
(a) The SRS system contains steering wheel assy, driver airbag, airbag wire harness, clock spring and
RCM.
2. SYSTEM SELF-CHECK.
(a) After turning the ignition switch to the “ON” position to start the SRS, the RCM will perform self-check
by the preset programme.
• If the airbag warning light goes out 4 seconds after lighting up, it means that the system is normal and
has passed the self-check. Then the RCM enters monitoring status.
• If the airbag warning light does not light up,flashes,or stays on, it means that the system is abnormal
and fail to pass the self-check.
System temperature: - 35 ～ 85 ℃
System volt: 12 ± 3 V
3. SYSTEM PRINCIPLES.
(a) When driving normally (including all kinds of road condition and interference), the RCM will not output
the ignition signal. The drive airbag is nonoperative.
(b) When a serious head-on collision happening, the RCM will output the ignition signal timely to deploy the
driver airbag.
(c) The deployed airbag absorbs the driver’s part energy in the collision to reduce the possible injuries.
WARNING
• The SRS airbag just provides a further protection besides the seat belt.
• To achieve the perfect protection, the driver must fasten the seat belt correctly and keep a good
posture.
• The technical parameters of airbag and RCM is matched each other. Never use airbag or RCM
components of other brands with this product together.
CAUTION
• It’s forbidden to make service in unauthorized dealer or by non-professional operators.
• Never the analog multimeter to measure the resistance of airbag. Otherwise the airbag will be
deployed unexpectedly when performing operations.
SYSTEM PERFORMANCE
1. AIRBAG.
(a) Fuzzy state (or critical condition)
62
• If the strength of head-on collision is less than the one caused by a straight running vehicle at the
speed of 13 ± 1 Km/h and a rigid wall (perpendicular to the vehicle direction), the airbag will be inoper-
ative.
• If the strength of head-on collision is more than the one caused by a straight running vehicle at the
speed of 23 ± 1 Km/h and a rigid wall (perpendicular to the vehicle direction), the airbag will be opera-
tive timely.
• If the strength of head-on collision is between the two caused by a straight running vehicle at the speed
of 13 ± 1 Km/h and 23 ± 1 Km/h and a rigid wall (perpendicular to the vehicle direction), the system will 62
be in fuzzy state (or critical condition). It will be normal that the airbag is either operative or inoperative.
(b) When a collision described below, the airbag must be deployed timely to protect the driver. In addition,
the relevant laws and regulations should be complied with.
• The collision is equal to the one caused by a straight running vehicle at the speed of 50 ± 2 Km/h and
a rigid wall (perpendicular to the vehicle direction).
a rigid column (perpendicular to the vehicle direction, φ = 250 mm).
a rigid wall (the angle with vehicle direction ≤ 30°).
a rigid wall (the angle with vehicle direction ≤ 40°).
(c) If the vehicle capsizes or suffers a collision which is not from the front, the airbag will not be deployed in
design.
(d) If the vehicle suffers a serious collision which is from the bottom, the airbag will be deployed possibly.
62-4 SUPPLEMENTAL RESTRAINT SYSTEM - SUPPLEMENTAL RESTRAINT SYSTEM
1. INSPECT HORN SWITCH ASSY (VEHICLE DOES NOT SUFFER A COLLISION).
(a) Check the diagnostic system. (Refer to “Chapter 04 diagnostics - supplemental restraint system,
precheck”)
(b) Visual check.

• Check for cuts, micro-cracks or marked discoloration on
the horn switch assy surface and in the grooved portion.
CAUTION
• Make sure there is no interference between the horn
• Make sure the clearance between the horn switch
assy and steering wheel is uniform.
If any fault is found, replace with a new part for necessary.
(Refer to “Chapter 62 supplemental restraint system, horn
switch assy, replacement”, “Chapter 51 steering column -
steering wheel assy, replacement”)
2. INSPECT HORN SWITCH ASSY (VEHICLE SUFFERS A COLLISION BUT AIRBAG IS NOT
DEPLOYED).
precheck”)
(b) Remove the horn switch assy. (Refer to “Chapter 62 supplemental restraint system, horn switch assy,
replacement”)
(c) Visual check.

• Check for cuts, micro-cracks or marked discoloration on
the horn switch assy surface and in the grooved portion.
• Check for cuts and cracks in wire harness and chipping

in connectors.
• Check for deformation on the steering wheel assy.
• Check whether the clock spring is damaged. 62
switch assy, replacement”, ”Chapter 62 supplemental restraint
system - clock spring, replacement”, “Chapter 51 steering
column - steering wheel assy, replacement”)
(d) Install the horn switch assy. (Refer to “Chapter 62

supplemental restraint system - horn switch assy, 62
replacement”)
CAUTION
switch assy, replacement”, “Chapter 51 steering column -
steering wheel assy, replacement”)
3. INSPECT HORN SWITCH ASSY (VEHICLE SUFFERS A COLLISION AND AIRBAG IS NOT
DEPLOYED).
precheck”)
(b) Replace the horn switch assy, clock spring, SRS wire harness and RCM with new parts. (Refer to
“Chapter 62 supplemental restraint system - horn switch assy, replacement”, “ Chapter 62
supplemental restraint system - clock spring, replacement”, “Chapter 62 supplemental restraint system
- RCM, replacement”)
CAUTION
If the airbag is deployed, be sure to replace all of the horn switch assy, clock spring, SRS wire harness
and RCM together.
4. INSPECT RCM (VEHICLE DOES NOT SUFFER A COLLISION).
precheck”)
5. INSPECT RCM (VEHICLE SUFFERS A COLLISION BUT AIRBAG IS NOT DEPLOYED).
precheck”)
6. INSPECT RCM (VEHICLE SUFFERS A COLLISION AND AIRBAG IS DEPLOYED).
precheck”)
(b) Replace the horn switch assy, clock spring, SRS wire harness and RCM with new parts. (Refer to
“Chapter 62 supplemental restraint system - horn switch assy, replacement”, “Chapter 62 supplemental
restraint system - clock spring, replacement”, “Chapter 62 supplemental restraint system - RCM,
replacement”)
62-6 SUPPLEMENTAL RESTRAINT SYSTEM - HORN SWITCH ASSY
HORN SWITCH ASSY

REPLACEMENT
1. PRECAUTION. (Refer to “Chapter 62 supplemental restraint system - supplemental restraint
system, precaution”)
3. DISCONNECT BATTERY POSITIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,
replacement”)
4. REMOVE HORN SWITCH ASSY.

(a) Turn the steering wheel to its straight position and face
the tires straight ahead.
(b) Using a hex spanner, loosen 2 inner hex bolts at the

bottom of the steering wheel.
(c) Remove the horn switch assy.

SUPPLEMENTAL RESTRAINT SYSTEM - HORN SWITCH ASSY 62-7
(d) Turn the horn switch assy over.

(e) Disconnect the clock spring wire harness connector.
(f) Disconnect the horn switch wire harness connector.
62
CAUTION
62
• Do not drag the clock spring wire harness.
• Do not disassemble the horn switch assy.
• When removing the horn switch assy or handling a
new horn switch assy, it should be placed with the
pad top surface upward. Placing it with the pad top
surface downward may lead to a serious accident if
the airbag accidently inflates. Also, do not place
horn switch assy on top of one another.
5. INSPECT HORN SWITCH ASSY.

(a) Visual check for cuts, micro-cracks and marked
discolouration on the horn switch assy top surface and in
the grooved portion.
6. INSTALL HORN SWITCH ASSY.

(a) Connect the clock spring wire harness connector.
(a) Connect the horn switch wire harness connector.
CAUTION
• Never use SRS parts removed from another vehicle.
Be sure to replace them with new parts when
replacing.
• If the horn switch assy has been dropped, or there
are cracks, dents or other faults, be sure to replace it
with a new one.
• Do not drag the clock spring wire harness and make
sure there is no interference between wire harness
and parts around.
NOTE
If hear a “click”, the connector is connected completely.
(b) Position the horn switch assy properly.
CAUTION
(c) Using a hex spanner, tighten 2 inner hex bolts at the

bottom of the steering wheel.
Torque: 10 N·m
7. CONNECT BATTERY POSITIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,
replacement”)
replacement”) 62
62
DISPOSAL
WARNING
• Never dispose of the horn switch assy with an undeployed airbag.
• The airbag produces a sizable exploding sound when being deployed. So be sure to perform the
operations outdoor where it will not create a nuisance to nearby residents.
• When deploying the airbag, be sure to use the

specified SST (SRS Airbag Deployment Tool) and
perform the operations in a place away from
electrical noise.
• When deploying a airbag, be sure to perform the

operation at least 10 m away from horn switch assy.
• The horn switch assy is very hot when the airbag is

depoyed. So leave it at least 30 minutes after
deployment.
• Use gloves and safety glasses when handling a horn
switch assy with the deployed airbag.
• Do not apply water, etc. to a horn switch assy with
the deployed airbag.
• Be sure to wash your hands with water after
completing the operation.
CAUTION
When disposing of the horn switch assy, be sure to follow the correct procedures described below to
deploy the airbag.
1. CHECK FUNCTION OF SST.

(a) Prepare a battery for the power supply to deploy the
airbag.
(b) Connect the SST to the battery. 62
NOTE
Do not connect the yellow connector which will be
connected to the airbag.
(c) Press the SST activation switch, check whether the

illumination lights up. 62
Standard: Light up
CAUTION
If the illumination lights up when the activation switch is
not pressed, SST malfunction is probable. Never use this
SST.
(d) Disconnect the SST from the battery.
2. DISPOSE OF HORN SWITCH ASSY.

CAUTION
• When disposing of the horn switch assy (with airbag), never use the customers’ vehicle to
deploy the airbag.
• Be sure to follow the procedures described below when deploying the airbag.
(a) Prepare a battery for the power supply to deploy the airbag.
(b) Remove the horn switch assy. (Refer to “Chapter 62 supplemental restraint system - horn switch assy,
replacement”)
(c) Tighten 2 bolts to the 2 bolt holes of the horn switch assy.
CAUTION
• Tighten the bolts by hands until the bolts become
hard to turn.
• Do not tighten the bolts too much.
• The bolts should be long enough.
(d) Connect the SST to the horn switch assy.

(e) Prepare a steel rim with tire and place it level.

(f) Separately tie the left and right sides of the horn switch
assy to the steel rim through the hub nut holes.
WARNING
• Be sure to tie down the horn switch assy with the
pad surface upward.
• Make sure the horn switch assy is tied down tightly.
NOTE
• To avoid damaging the SST connector and wire
harness, secure some slack for the SST wire harness
inside the steel rim.
(g) Connect the SST to the battery.

(h) Move the SST at least 10 m away from the horn switch
assy.
(i) Cover the horn switch assy with a carton or tires.

CAUTION
• Make sure the horn switch assy is covered
completely.
• Weight the carton down with at least 20 Kg.
• Place at least 3 tires. In addition, always use the
redundant tires which may be marked by the airbag
deployment.
(j) Press the activation switch to deploy the airbag.

WARNING
Make sure nobody is within 10 m away from the horn switch
assy.
NOTE
The airbag is deployed simultaneously when the LED of the
SST activation switch lights up.
(k) Remove the horn switch assy from the steel rim.
(l) Put the horn switch assy in a plastic bag and tie the end
tightly. Dispose of it in the same way as other general
parts disposal. 62
WARNING
• The horn switch assy is very hot when the airbag is
depoyed. So leave it at least 30 minutes after
deployment.
• Use gloves and safety glasses when handling a horn
switch assy with the deployed airbag.
• Do not apply water, etc. to a horn switch assy with 62
the deployed airbag.
• Be sure to wash your hands with water after
completing the operation.
62-14 SUPPLEMENTAL RESTRAINT SYSTEM - CLOCK SPRING
CLOCK SPRING
REPLACEMENT
overhaul”)
overhaul”)
6. REMOVE COMBINATION SWITCH UPPER COVER. (Refer to “Chapter 51 steering column -
combination switch assy, replacement”)
7. REMOVE COMBINATION SWITCH LOWER COVER. (Refer to “Chapter 51 steering column -
8. REMOVE CLOCK SPRING.

(a) Disconnect 2 connectors:
(b) Remove the clock spring with 4 screws.
9. INSTALL CLOCK SPRING.

(a) Install the clock spring and tighten 4 bolts.
SUPPLEMENTAL RESTRAINT SYSTEM - CLOCK SPRING 62-15
(b) Connect 2 connectors:

62
10. INSTALL COMBINATION SWITCH UPPER COVER. (Refer to “Chapter 51 steering column -
combination switch assy, replacement”) 62
11. INSTALL COMBINATION SWITCH LOWER COVER. (Refer to “Chapter 51 steering column -
12. CENTER CLOCK SPRING.

(a) Make sure the ignition switch is in the “LOCK” position.
(b) Make sure the battery positive and negative cables are
disconnected.
CAUTION
Do not start the operation within 90 seconds after
diconnecting the cables.
NOTE
There is an information label on the clock spring. Follow
the instructions on the label.
(c) Rotate the cable counterclockwise by hands until it
(d) Rotate the cable clockwise about 2.5 turns to align the
marks.
NOTE
the center.
NOTE
clock spring.
62-16 SUPPLEMENTAL RESTRAINT SYSTEM - CLOCK SPRING
overhaul”)
overhaul”)
replacement”)
SUPPLEMENTAL RESTRAINT SYSTEM - RCM 62-17
RCM
REPLACEMENT
1. PRECAUTION. (Refer to “Chapter 51 steering column - steering system, precaution”) 62
4. REMOVE RCM COVER.

(a) Loosen 2 bolts and remove the RCM cover.
62
NOTE
The RCM cover is on the front carpet assy which is in front
of the middle platform assy and under the dashboard
ashtray assy.
5. REMOVE RCM.
(b) Make sure the battery positive and negative cables are disconnected.
CAUTION
• Do not start the operation within 90 seconds after diconnecting the cables.
• Never strike the RCM when it is energized.
(c) Disconnect the RCM wire harness connector.
(d) Loosen 4 nuts and remove the RCM.

62-18 SUPPLEMENTAL RESTRAINT SYSTEM - RCM
6. REMOVE RCM BRACKET.

(a) Loosen 4 bolts and remove the RCM bracket.
7. INSTALL RCM BRACKET.

(a) Position the RCM bracket properly.
(b) Tighten 4 bolts by the sequence shown in the illustration.

8. INSTALL RCM.
(b) Make sure the battery positive and negative cables are disconnected.
CAUTION
• Do not start the operation within 90 seconds after diconnecting the cables.
• Never strike the RCM when it is energized.
(c) Position the RCM properly.

NOTE
Position the RCM along the direction shown in the
information label.
SUPPLEMENTAL RESTRAINT SYSTEM - RCM 62-19
(d) Tighten 4 bolts by the sequence shown in the illustration.

62
(e) Connect the RCM wire harness connector.

62
replacement”)
MEMO
SEAT BELT
63
SEAT BELT SYSTEM ........................................................................ 63-1
PRECAUTION.............................................................................. 63-1
SEAT BELT WARNING SYSTEM...................................................... 63-2
INSPECTION ............................................................................... 63-3
DRIVER / ASSISTANT DRIVER SEAT BELT ................................... 63-4 63
COMPONENTS ........................................................................... 63-4
ADJUSTMENT ............................................................................. 63-5
PASSENGER SEAT BELT ................................................................ 63-7
COMPONENTS ........................................................................... 63-7
BUCKLE ASSY ................................................................................ 63-19
REPLACEMENT ........................................................................ 63-19
RETRACTOR ASSY......................................................................... 63-22
OVERHAUL ............................................................................... 63-22
ANCHOR ADJUSTER ASSY ........................................................... 63-27
REPLACEMENT ........................................................................ 63-27
SEAT BELT - SEAT BELT SYSTEM 63-1
SEAT BELT SYSTEM

SEAT BELT
PRECAUTION
WARNING 63
• Once any fault is found in the system, be sure to replace the parts (including mesh belt, retrac-
tor, lock catch & latch, anchor adjuster, bolt and nut).
• The seat belt which is not used in a collision should also be inspected and replaced if found any
damage or working improperly.
63
63-2 SEAT BELT - SEAT BELT WARNING SYSTEM
SEAT BELT WARNING SYSTEM

1. Fuse (Damaged) -
Chapter 83 instrument panel - instrument

2. Instrument cluster (Damaged) cluster, replacement
Seat belt warning light
does not light up Chapter 63 seat belt - buckle assy,
3. Electric buckle assy (Damaged) replacement
4. Wire harness (Open or short) -

SEAT BELT - SEAT BELT WARNING SYSTEM 63-3
INSPECTION
1. INSPECT ELECTRIC BUCKLE ASSY.
(a) Check the resistance. 63
Standard:
Specified
Driver seat belt latch plate Terminal
condition
Pull out 1-2 ＜2Ω
63
Insert 1-2 ＞ 1 MΩ
63-4 SEAT BELT - DRIVER / ASSISTANT DRIVER SEAT BELT
DRIVER / ASSISTANT DRIVER SEAT BELT

COMPONENTS
1 Driver Seat Belt Anchor Adjuster Assy Assistant Driver Seat Mesh belt With
5
Retractor Assy
2 Driver Seat Mesh belt With Retractor Assy
Assistant Driver Seat Belt Anchor Adjuster
3 Electric Buckle Assy 6
Assy
4 Buckle Assy
SEAT BELT - DRIVER / ASSISTANT DRIVER SEAT BELT 63-5
ADJUSTMENT
1. ADJUST DRIVER SEAT BELT ANCHOR ADJUSTER.
(a) Upward: 63
• Slide the driver seat belt anchor adjuster upward directly
to the right position.
NOTE
The mesh belt should cross the shoulder center.
63
(b) Downward:
• Press the button and hold it.
• Slide the driver seat belt anchor adjuster down to the

right position.
NOTE
The mesh belt should cross the shoulder center.
63-6 SEAT BELT - DRIVER / ASSISTANT DRIVER SEAT BELT
• Release the button.
• Attempt to slide the anchor adjuster downward to make

sure it is locked completely.
2. ADJUST ASSISTANT DRIVER SEAT BELT ANCHOR ADJUSTER.

NOTE
Adjust the assistant driver seat belt anchor adjuster by the same procedures as the driver seat belt
anchor adjuster.
SEAT BELT - PASSENGER SEAT BELT 63-7
PASSENGER SEAT BELT

COMPONENTS
THE SHORT WHEELBASE VEHICLE EQUIPPED WITH INTERMEDIATE SEATS 63
(2+2+3)
63
1 Mesh belt With Latch Plate Assy 3 Dual Buckle Assy
2 Buckle Assy 4 Mesh belt With Latch Plate And Buckle Assy
63-8 SEAT BELT - PASSENGER SEAT BELT
THE SHORT WHEELBASE VEHICLE EQUIPPED WITH INTERMEDIATE SEATS

(2+3+3)
2 Mesh belt With Buckle Assy 4 Mesh belt With Latch Plate And Buckle Assy
THE SHORT WHEELBASE VEHICLE EQUIPPED WITH HIGH-GRADE SEATS

(2+2+2)
63
63
Front Passenger Seat Mesh belt With Front Passenger Seat Mesh belt With
1 4
Retractor Assy RH Retractor Assy LH
2 Mesh belt With Latch Plate Assy Rear Passenger Seat Mesh belt With
5
Retractor Assy
3 Buckle Assy

(2+2+3)
Front Passenger Seat Mesh belt With Rear Passenger Seat Mesh belt With
1 5
Retractor Assy RH Retractor Assy
Front Passenger Seat Mesh belt With

4
Retractor Assy LH
THE LONG WHEELBASE VEHICLE EQUIPPED WITH LOW-END SEATS

(2+2+3)
63
63
1 Mesh belt With Latch Plate Assy 3 Mesh belt With Latch Plate And Buckle Assy
2 Dual Buckle Assy


(2+3+3)

(2+2+2+3)
63
63
2 Dual Buckle Assy


(2+3+3+3)
1 Mesh belt With Latch Plate Assy 3 Mesh belt With Buckle Assy
2 Dual Buckle Assy 4 Mesh belt With Latch Plate And Buckle Assy
THE LONG WHEELBASE VEHICLE EQUIPPED WITH INTERMEDIATE SEATS

(2+2+3)
63
63

(2+2+2+3)
2 Dual Buckle Assy


(2+3+3+3)
63
63
THE LONG WHEELBASE VEHICLE EQUIPPED WITH HIGH-GRADE SEATS

(2+2+2+3)
SEAT BELT - BUCKLE ASSY 63-19
BUCKLE ASSY
REPLACEMENT
1. REMOVE ELECTRIC BUCKLE ASSY. 63
(a) Remove the driver seat assy. (Refer to “Chapter 84 seat - driver / assistant driver seat, removal &
(b) Loosen the screw.
63
(c) Remove the reclining adjuster trim cover electric buckle

side by the sequence shown in the illustration.
NOTE
• Move the trim cover backward to separate 2 slots.
• Pull outward and remove the trim cover.
(d) Loosen completely the bolt attaching the electric buckle

to the driver seat reclining adjuster.
63-20 SEAT BELT - BUCKLE ASSY
(e) Remove the electric buckle assy.
(f) Pull out the electric buckle wire harness through the
aperture between cushion pad and reclining adjuster.
CAUTION
Be careful. Do not damage the electric buckle wire harness
connector.
2. REMOVE BUCKLE ASSY.

NOTE
• Remove the buckle assy by the same procedures as the electric buckle assy.
• Remove the buckle assy in step (e).
• Skip step (f).
3. INSTALL ELECTRIC BUCKLE ASSY.

(a) Put the electric buckle wire harness connector through
the aperture between cushion pad and reclining adjuster.
CAUTION
connector.
(b) Position the electric buckle assy properly.

SEAT BELT - BUCKLE ASSY 63-21
(c) Tighten the bolt.

63
63
(d) Install the reclining adjuster trim cover electric buckle
NOTE
• Push the trim cover inward to align the slots.
• Move the trim cover forward to position it properly.
(e) Tighten the screw.
4. INSTALL BUCKLE ASSY.

NOTE
• Install the buckle assy by the same procedures as the electric buckle assy.
• Position the buckle assy properly in step (b).
• Skip step (a).
63-22 SEAT BELT - RETRACTOR ASSY
RETRACTOR ASSY
OVERHAUL
1. REMOVE DRIVER SEAT MESH BELT WITH
RETRACTOR ASSY.
(a) Remove the lower anchor trim cover by the sequence
shown in the illustration.
NOTE
• Pull the trim cover outward.
• Move the trim cover upward to show the bolt.
(b) Loosen the bolt completely.
(c) The vehicle without the sliding door LH:

• Remove the side wall front lower guard board LH. (Refer
to “Chapter 88 exterior and interior trim - side wall guard
board, replacement”)
The vehicle with the sliding door LH:
• Remove the B pillar lower inner guard board. (Refer to
“Chapter 88 exterior and interior trim - side wall guard
SEAT BELT - RETRACTOR ASSY 63-23
(d) Remove the upper anchor trim cover.
63
63
(e) Loosen the bolt completely.
(f) Loosen the bolt.

(g) Remove the driver seat mesh belt with retractor assy.
CAUTION
Never disassemble the retractor.
2. REMOVE ASSISTANT DRIVER SEAT MESH BELT WITH RETRACTOR ASSY.

NOTE
Remove the assistant driver seat mesh belt with retractor by the same procedures as the driver seat
mesh belt with retractor assy.
3. INSPECT RETRACTOR.
(a) Check whether the mesh belt is locked when tilting the
retractor.
• Within 15° of tilt in all the directions, check that the mesh
belt should not be locked.
• Over 45° of tilt in all the directions, check that the mesh
belt should be locked.
If the operation is out of the specification, replace with a new
driver / assistant driver seat mesh belt with retractor assy. (Refer
to “Chapter 63 seat belt - retractor assy, overhaul”)
4. INSTALL DRIVER SEAT MESH BELT WITH

RETRACTOR ASSY.
(a) Position the retractor properly.
(b) Tighten the bolt.
(c) Tighten the bolt.

CAUTION
Make sure the mesh belt is neat without snarling.
SEAT BELT - RETRACTOR ASSY 63-25
(d) Install the upper anchor trim cover.
63
63
(e) The vehicle without sliding door LH:

• Install the side wall front lower guard board LH. (Refer to
The vehicle with the sliding door LH:
• Install the B pillar lower inner guard board. (Refer to
(f) Tighten the bolt.

CAUTION
(g) Install the lower anchor trim cover by the sequence

NOTE
• Move the trim cover down to cover the bolt.
• Press the trim cover down.
5. INSTALL ASSISTANT DRIVER SEAT MESH BELT WITH RETRACTOR ASSY.

NOTE
Install the assistant driver seat mesh belt with retractor by the same procedures as the driver seat
mesh belt with retractor assy.
6. INSPECT DRIVER / ASSISTANT DRIVER SEAT MESH BELT WITH RETRACTOR ASSY.
(a) Check mesh belt locking operation.
• The mesh belt should be locked when being dragged quickly.
(b) Check children protection operation.
• After extracting the mesh belt out of the retractor completely, the retractor enter LOCK mode. In this
mode, the mesh belt only can be contacted.
• When the mesh belt contact fully, the retractor will recover to NORMAL mode from LOCK mode.
NOTE
This function is used for the children protector applied to the vehicle.
If the opertation is out of the specification, replace with a new driver / assistant driver seat mesh
belt with retractor assy. (Refer to “Chapter 63 seat belt - retractor assy, overhaul”)
SEAT BELT - ANCHOR ADJUSTER ASSY 63-27
ANCHOR ADJUSTER ASSY

REPLACEMENT
63
1. REMOVE DRIVER SEAT BELT ANCHOR ADJUSTER.
(a) Remove the upper anchor trim cover.
63
(b) Loosen the bolt completely.
(c) Remove the B pillar upper inner guard board. (Refer to

63-28 SEAT BELT - ANCHOR ADJUSTER ASSY
(d) Slide the cover to the highest position by hand directly.
(e) Loosen the lower bolt.

(f) Press the lock plate by screwdriver and slide the adjuster
to the lowest position.
63
63
(g) Loosen the upper bolt.

(h) Remove the driver seat belt anchor adjuster.
2. REMOVE ASSISTANT DRIVER SEAT BELT ANCHOR ADJUSTER ASSY.

NOTE
Remove the assistant driver seat belt anchor adjuster by the same procedures as the driver seat belt
anchor adjuster.
3. INSTALL DRIVER SEAT BELT ANCHOR ADJUSTER.

(a) Position the driver seat belt anchor adjuster assy
properly.
(b) Press the lock plate by screwdriver and slide the adjuster
to the lowest position.
63
63
(c) Tighten the upper bolt.

(d) Slide the anchor adjuster to the highest position by hand

directly.
(e) Tighten the lower bolt.
(f) Install the B pillar upper inner guard board. (Refer to

boad, replacement”)
(g) Tighten the bolt.

CAUTION
63
63
(h) Install the upper anchor trim cover.
4. INSTALL ASSISTANT DRIVER SEAT BELT ANCHOR ADJUSTER.

NOTE
Install the assistant driver seat belt anchor adjuster by the same procedures as the driver seat belt
anchor adjuster.
MEMO
LIGHTING
64
LIGHTING SYSTEM ........................................................................... 64-1
PRECAUTION.............................................................................. 64-1
COMPONENTS ........................................................................... 64-2
FRONT COMBINATION LAMP ASSY LH ......................................... 64-4 64
REPLACEMENT .......................................................................... 64-4
ADJUSTMENT ............................................................................. 64-6
FRONT COMBINATION LAMP BULB LH......................................... 64-7
REPLACEMENT .......................................................................... 64-7
FRONT FOG LAMP ASSY LH ......................................................... 64-14
REPLACEMENT ........................................................................ 64-14
ADJUSTMENT ........................................................................... 64-16
FRONT FOG LAMP BULB LH......................................................... 64-17
REPLACEMENT ........................................................................ 64-17
TURN SIGNAL LAMP IN OUTSIDE MIRROR ................................. 64-19
REPLACEMENT ........................................................................ 64-19
REAR COMBINATION LAMP ASSY LH ......................................... 64-20
REPLACEMENT ........................................................................ 64-20
REAR COMBINATION LAMP ASSY BULB LH .............................. 64-22
REPLACEMENT ........................................................................ 64-22
HIGH-MOUNTED STOP LAMP ASSY............................................. 64-27
REPLACEMENT ........................................................................ 64-27
LICENCE LAMP ASSY LH .............................................................. 64-28
REPLACEMENT ........................................................................ 64-28
REAR FOG LAMP ASSY LH ........................................................... 64-30
REPLACEMENT ........................................................................ 64-30
FRONT INDOOR LAMP ASSY ........................................................ 64-32
REPLACEMENT ........................................................................ 64-32
FRONT INDOOR LAMP BULB ....................................................... 64-35
REPLACEMENT ........................................................................ 64-35
INDOOR ROOF LAMP ASSY LH .................................................... 64-37
REPLACEMENT ........................................................................ 64-37
INDOOR ROOF LAMP BULB LH ................................................... 64-38
REPLACEMENT ........................................................................ 64-38
REAR INDOOR LAMP ASSY .......................................................... 64-40
REPLACEMENT ........................................................................ 64-40
REAR INDOOR LAMP BULB ......................................................... 64-42
REPLACEMENT ........................................................................ 64-42
STEP LAMP ASSY........................................................................... 64-43
REPLACEMENT ........................................................................ 64-43
STEP LAMP BULB .......................................................................... 64-45
REPLACEMENT ........................................................................ 64-45
HEADLAMP DIMMER SWITCH ASSY ............................................ 64-46
REPLACEMENT ........................................................................ 64-46
REAR FOG LAMP SWITCH ASSY.................................................. 64-47
REPLACEMENT ........................................................................ 64-47
LIGHTING - LIGHTING SYSTEM 64-1
LIGHTING SYSTEM
LIGHTING
PRECAUTION
1. LIGHTING SYSTEM PRECAUTION. 64
(a) Even if a thin film of oil is left on the surface of the halogen lamp, its service life will be shortened
because the lamp will be burm at a higher temperature.
(b) Handle any halogen lamp with great care. Dropping, hitting or damaging the bulb in any way may result
in it exploding and scattering because the internal pressure is high. 64
(c) Always use a bulb of the same wattage for replacement. Be sure not to touch the bulb immediately.
(d) Firmly reinstall the socket after bulb replacement. The lens may become cloudy or the light cavity may
fill with water through the gaps around the socket.
64-2 LIGHTING - LIGHTING SYSTEM
COMPONENTS
LIGHTING - LIGHTING SYSTEM 64-3
1 Front Combination Lamp Assy RH 8 Front Fog Lamp Assy RH
2 Front Indoor Lamp Assy 9 Rear Combination Lamp Assy LH
3 Indoor Roof Lamp 10 High-mounted Stop Lamp Assy 64
4 Rear Indoor Lamp Assy 11 Rear Combination Lamp Assy RH
5 Step Lamp Assy 12 Rear Fog Lamp Assy RH

64
6 Front Combination Lamp Assy LH 13 Rear Fog Lamp Assy LH
7 Front Fog Lamp Assy LH 14 License Plate Lamp Assy

64-4 LIGHTING - FRONT COMBINATION LAMP ASSY LH
FRONT COMBINATION LAMP ASSY LH

REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE CABLE.
2. REMOVE FRONT COMBINATION LAMP ASSY LH.
(a) Remove the front grille. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”)
(b) Remove front bumper assy. (Refer to “Chapter 88 exterior and interior trim - front bumper assy,
replacement”)
(c) Remove 4 bolts and front combination lamp assy LH.
(d) Disconnect 2 connectors.
(e) Remove the front combination lamp assy LH.

LIGHTING - FRONT COMBINATION LAMP ASSY LH 64-5
3. REMOVE FRONT COMBINATION LAMP ASSY RH.

NOTE
Remove the RH side by the same procedures as the LH side.
64
4. INSTALL FRONT COMBINATION LAMP ASSY LH.
(a) Connect 2 connectors.
64
(b) Install the front combination lamp assy LH with 4 bolts.
(c) Install front bumper assy. (Refer to “Chapter 88 exterior

and interior trim - front bumper assy, replacement”)
(d) Install the front grille. (Refer to “Chapter 88 exterior and
interior trim - front grille, replacement”)
5. INSTALL FRONT COMBINATION LAMP ASSY RH.

NOTE
Install the RH side by the same procedures as the LH side.
6. CONNECT BATTERY NEGATIVE CABLE.

64-6 LIGHTING - FRONT COMBINATION LAMP ASSY LH
ADJUSTMENT
1. ADJUST THE HEADLAMP AIMING.
(a) Place the vehicle in the following conditions.
• The area around the headlight is not deformed.
• The vehicle is parked on a level surface.
• Tire inflation pressure is in the specified value. (Refer to “Chapter 33 tire and wheel - tire and wheel
system, on-vehicle inspection,”)
• A driver is in the driver’s seat or let something weight 73 Kg on the seat of the vehicle; the vehicle is
ready for driving. (with a tank full)
(b) Check the headlamp aiming.

• Park the vehicle at the flat field and make the lens
surface of the headlamps be 10 m away from the
screen.The curtain or flat wall can be used as the screen.
• Start the engine.
• Turn the headlamps on.
• Check that the headlamps properly strike the position
NOTE
A and B shows the position of the headlamps; H shows the
height of the headlamps; L1 and L2 shows the distance
between the center of headlamps and the center of the
vehicle.
• Adjust the headlamps if necessary.
(c) Adjust the adjusting bolts to adjust the headlamp aim to

be within the specified range.
LIGHTING - FRONT COMBINATION LAMP BULB LH 64-7
FRONT COMBINATION LAMP BULB LH

REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE CABLE. 64
2. REMOVE FRONT COMBINATION LAMP ASSY LH. (Refer to “Chapter 64 lighting - front
combination lamp assy LH, replacement”)
3. REMOVE HEADLAMP BULB LH. 64

(a) Remove the cap as the hint shows on the back of the
cap.
(b) Remove the steel wire.

64-8 LIGHTING - FRONT COMBINATION LAMP BULB LH
(d) Remove the headlamp bulb LH.
4. REMOVE HEADLAMP BULB RH.

NOTE
5. REMOVE POSITION LAMP BULB LH.

cap.
(b) Remove the lamp socket.
64
64
(c) Remove the position lamp bulb.
6. REMOVE POSITION LAMP BULB RH.

NOTE
7. REMOVE FRONT TURN SIGNAL LAMP BULB LH.

(a) Remove the lamp socket as illustrated.
(b) Remove the front turn signal lamp bulb as illustrated.

NOTE
Gently depress the bulb before rotating it.
8. REMOVE FRONT TURN SIGNAL LAMP BULB RH.

NOTE
9. INSTALL FRONT TURN SIGNAL LAMP BULB LH.

(a) Install the front turn signal lamp bulb as illustrated.
NOTE
(b) Install the lamp socket as illustrated.
10. INSTALL FRONT TURN SIGNAL LAMP BULB RH.

NOTE
11. INSTALL POSITION LAMP BULB LH.

(a) Install the position lamp to the lamp socket.
64
64
(b) Install the lamp socket.
(c) Install the cap as the hint shows on the back of the cap.
12. INSTALL POSITION LAMP BULB RH.

NOTE
13. INSTALL HEADLAMP BULB LH.

(a) Connect the connector.
(b) Install the headlamp bulb and the steel wire.
(c) Install the cap as the hint shows on the back of the cap.
14. INSTALL FRONT COMBINATION LAMP ASSY LH. (Refer to “Chapter 64 lighting - front
combination lamp assy LH, replacement”)
15. INSTALL HEADLAMP BULB RH.
NOTE
64
64
64-14 LIGHTING - FRONT FOG LAMP ASSY LH
FRONT FOG LAMP ASSY LH

REPLACEMENT
2. REMOVE FRONT FOG LAMP ASSY LH.
(a) Remove front bumper assy. (Refer to “Chapter 88 exterior and interior trim - front bumper assy,
replacement”)
(b) Remove 3 bolts.
(c) Remove the front fog lamp assy LH.
3. INSTALL FRONT FOG LAMP ASSY LH.

(a) Install the front fog lamp assy LH with 3 bolts.
LIGHTING - FRONT FOG LAMP ASSY LH 64-15
(b) Install front bumper assy. (Refer to “Chapter 88 exterior and interior trim - front bumper assy,
replacement”)
4. INSTALL FRONT FOG LAMP ASSY RH.
NOTE
64
64
64-16 LIGHTING - FRONT FOG LAMP ASSY LH
ADJUSTMENT
1. PLACE THE VEHICLE IN THE FOLLOWING CONDITIONS.
(a) Tire inflation pressure is in the specified value. (Refer to “Chapter 33 tire and wheel - tire and wheel
system, on-vehicle inspection”)
(b) Start the engine.
2. ADJUST THE FRONT FOG LAMP AIMING.

(a) Adjust the adjusting bolt to adjust the front fog lamp aim
in the vertical direction.
LIGHTING - FRONT FOG LAMP BULB LH 64-17
FRONT FOG LAMP BULB LH

REPLACEMENT
2. REMOVE FRONT FOG LAMP ASSY LH. (Refer to “Chapter 64 lighting - front fog lamp assy LH,
replacement”)
3. REMOVE FRONT FOG LAMP BULB LH. 64

cap.
(b) Disconnect the connector.
(c) Remove the front fog lamp bulb LH.

64-18 LIGHTING - FRONT FOG LAMP BULB LH
4. REMOVE FRONT FOG LAMP BULB RH.

NOTE
5. INSTALL FRONT FOG LAMP BULB LH.

(a) Connect the connector and install the front fog lamp bulb
LH.
(b) Install the cap as the hint shows on the back of the cap.
6. INSTALL FRONT FOG LAMP ASSY LH. (Refer to “Chapter 64 lighting - front fog lamp assy LH,
replacement”)
7. INSTALL FRONT FOG LAMP BULB RH.
NOTE
LIGHTING - TURN SIGNAL LAMP IN OUTSIDE MIRROR 64-19
TURN SIGNAL LAMP IN OUTSIDE MIRROR

REPLACEMENT
2. REMOVE THE TURN SIGNAL LAMP IN OUTSIDE MIRROR LH.
(a) Disassemble the outside mirror LH. (Refer to “Chapter 82 windshield - outside mirror, replacement”)
(b) Disconnect the connector and remove 2 bolts. 64
(c) Remove the turn signal lamp in outside mirror LH.
3. REMOVE TURN SIGNAL LAMP IN OUTSIDE MIRROR RH.

NOTE
4. INSTALL THE TURN SIGNAL LAMP IN OUTSIDE

MIRROR LH.
(a) Connect the connector and install 2 bolts.
(b) Assemble the outside mirror LH. (Refer to “Chapter 82

windshield - outside mirror, replacement”)
5. INSTALL THE TURN SIGNAL LAMP IN OUTSIDE MIRROR RH.
NOTE
64-20 LIGHTING - REAR COMBINATION LAMP ASSY LH
REAR COMBINATION LAMP ASSY LH

REPLACEMENT
2. REMOVE REAR COMBINATION LAMP ASSY LH.

(a) Remove 3 bolts.
(c) Remove the rear combination lamp assy LH.

LIGHTING - REAR COMBINATION LAMP ASSY LH 64-21
3. REMOVE REAR COMBINATION LAMP ASSY RH.

NOTE
64
4. INSTALL REAR COMBINATION LAMP ASSY LH.
(a) Connect the connector and install the rear combination
lamp to the carriage body.
64
5. INSTALL REAR COMBINATION LAMP ASSY RH.

NOTE
64-22 LIGHTING - REAR COMBINATION LAMP ASSY BULB LH
REAR COMBINATION LAMP ASSY BULB LH

REPLACEMENT
2. REMOVE LEFT AND RIGHT REAR COMBINATION LAMP ASSY. (Refer to “Chapter 64 lighting -
rear combination lamp assy LH, replacement”)
3. REMOVE REAR TURN SIGNAL LAMP BULB LH.

(b) Remove the rear turn signal lamp bulb as illustrated.

NOTE
4. REMOVE REAR TURN SIGNAL LAMP BULB RH.

NOTE
LIGHTING - REAR COMBINATION LAMP ASSY BULB LH 64-23
5. REMOVE REAR STOP LAMP BULB LH.

64
64
(b) Remove the rear stop lamp bulb as illustrated.

NOTE
6. REMOVE REAR STOP LAMP BULB RH.

NOTE
7. REMOVE REAR BACK-UP LAMP BULB LH.

(b) Remove the rear back-up lamp bulb as illustrated.

NOTE
8. REMOVE REAR BACK-UP LAMP BULB RH.

NOTE
9. INSTALL REAR BACK-UP LAMP BULB LH.

(a) Install the rear back-up lamp bulb as illustrated.
NOTE
10. INSTALL REAR BACK-UP LAMP BULB RH.

NOTE
LIGHTING - REAR COMBINATION LAMP ASSY BULB LH 64-25
11. INSTALL REAR STOP LAMP BULB LH.

(a) Install the rear stop lamp bulb as illustrated.
NOTE
64
64
12. INSTALL REAR STOP LAMP BULB RH.

NOTE
13. INSTALL REAR TURN SIGNAL LAMP BULB LH.
(a) Install the lamp bulb as illustrated.

NOTE
14. INSTALL REAR TURN SIGNAL LAMP BULB RH.

NOTE
15. INSTALL LEFT AND RIGHT REAR COMBINATION LAMP ASSY. (Refer to “Chapter 64 lighting -
rear combination lamp assy LH, replacement”)
LIGHTING - HIGH-MOUNTED STOP LAMP ASSY 64-27
HIGH-MOUNTED STOP LAMP ASSY

REPLACEMENT
2. REMOVE SPOILER ASSY. (Refer to “Chapter 88 exterior and interior trim - spoiler assy,
replacement”)
3. REMOVE HIGH-MOUNTER STOP LAMP ASSY. 64
4. INSTALL HIGH-MOUNTER STOP LAMP ASSY.

5. INSTALL SPOILER ASSY. (Refer to “Chapter 88 exterior and interior trim - spoiler assy,
replacement”)
64-28 LIGHTING - LICENCE LAMP ASSY LH
LICENCE LAMP ASSY LH

REPLACEMENT
2. REMOVE LICENCE LAMP ASSY LH.

(b) Remove the lampshade.
(c) Remove the bulb of licence lamp.
3. REMOVE LICENCE LAMP ASSY RH.

NOTE
4. INSTALL LICENCE LAMP ASSY LH.

(a) Install the bulb of licence lamp.
LIGHTING - LICENCE LAMP ASSY LH 64-29
(b) Install the lampshade.
64
64
(c) Tighten 2 screws.
5. INSTALL LICENCE LAMP ASSY RH.

NOTE
64-30 LIGHTING - REAR FOG LAMP ASSY LH
REAR FOG LAMP ASSY LH

REPLACEMENT
2. REMOVE REAR FOG LAMP ASSY LH.
(a) Remove the rear bumper assy. (Refer to “Chapter 88 exterior and interior trim - rear bumper assy,
replacement”)
(b) Remove the lamp socket as illustrated.
(c) Remove the rear fog lamp bulb as illustrated.

NOTE
(d) Remove 2 screws of rear fog lamp assy LH.
(e) Remove rear fog lamp assy LH.

LIGHTING - REAR FOG LAMP ASSY LH 64-31
3. REMOVE REAR FOG LAMP ASSY LH.

NOTE
64
4. INSTALL REAR FOG LAMP ASSY LH.
(a) Install the rear fog lamp assy LH with 2 screws.
64
(b) Install the rear fog lamp bulb as illustrated.
(c) Install the lamp socket as illustrated.
(d) Install the rear bumper assy. (Refer to “Chapter 88

exterior and interior trim - rear bumper assy,
replacement”)
5. INSTALL REAR FOG LAMP ASSY LH.
NOTE
64-32 LIGHTING - FRONT INDOOR LAMP ASSY
FRONT INDOOR LAMP ASSY

REPLACEMENT
2. REMOVE FRONT INDOOR LAMP ASSY.

(a) Remove the cover of screws.
(b) Remove 2 screws.

LIGHTING - FRONT INDOOR LAMP ASSY 64-33
(d) Remove the front indoor lamp assy.
64
64
3. INSTALL FRONT INDOOR LAMP ASSY.

(b) Install the front indoor lamp assy with 2 screws.

64-34 LIGHTING - FRONT INDOOR LAMP ASSY
(c) Install the cover of screws.

LIGHTING - FRONT INDOOR LAMP BULB 64-35
FRONT INDOOR LAMP BULB

REPLACEMENT
2. REMOVE THE LAMPSHADE OF FRONT INDOOR

LAMP.
64
3. REMOVE FRONT INDOOR LAMP BULBS.
4. INSTALL FRONT INDOOR LAMP BULBS.

64-36 LIGHTING - FRONT INDOOR LAMP BULB
5. INSTALL THE LAMPSHADE OF FRONT INDOOR

LAMP.

LIGHTING - INDOOR ROOF LAMP ASSY LH 64-37
INDOOR ROOF LAMP ASSY LH

REPLACEMENT
2. REMOVE INDOOR ROOF LAMP ASSY LH.
(a) Remove the vent grille with switch assy LH. (Refer to “Chapter 88 exterior and interior - trim,
replacement)
64
(b) Remove indoor roof lamp assy LH.
3. REMOVE INDOOR ROOF LAMP ASSY RH.

NOTE
4. INSTALL INDOOR ROOF LAMP ASSY LH.

(a) Install the indoor roof lamp assy LH.
(b) Install the vent grille with switch assy LH. (Refer to
“Chapter 88 exterior and interior - trim, replacement)
5. INSTALL INDOOR ROOF LAMP ASSY RH.
NOTE
64-38 LIGHTING - INDOOR ROOF LAMP BULB LH
INDOOR ROOF LAMP BULB LH

REPLACEMENT
2. REMOVE INDOOR ROOF LAMP BULB LH.

(a) Use a screwdriver, remove the lampshade of indoor roof
lamp LH.
NOTE
Be careful not to damage the lampshade. Tape the
screwdriver tip before using it.
(b) Remove indoor roof lamp bulb LH.
3. REMOVE INDOOR ROOF LAMP BULB RH.

NOTE
4. INSTALL INDOOR ROOF LAMP BULB LH.

(a) Install indoor roof lamp bulb LH.
LIGHTING - INDOOR ROOF LAMP BULB LH 64-39
(b) Install the lampshade of indoor roof lamp LH.
64
64
5. INSTALL INDOOR ROOF LAMP BULB RH.

NOTE
64-40 LIGHTING - REAR INDOOR LAMP ASSY
REAR INDOOR LAMP ASSY

REPLACEMENT
2. REMOVE REAR INDOOR LAMP ASSY.

(a) Use a screwdriver, remove the lampshade of rear indoor
lamp assy.
NOTE
(b) Remove 2 screws from rear indoor lamp assy.
(c) Disconnect the connector of rear indoor lamp assy.
(d) Remove the rear indoor lamp assy.

LIGHTING - REAR INDOOR LAMP ASSY 64-41
3. INSTALL REAR INDOOR LAMP ASSY.

(a) Connect the connector of rear indoor lamp assy.
64
64
(b) Install the rear indoor lamp with 2 screws.
(c) Install the lampshade of rear indoor lamp assy.

64-42 LIGHTING - REAR INDOOR LAMP BULB
REAR INDOOR LAMP BULB

REPLACEMENT
2. REMOVE REAR INDOOR LAMP BULB.
(a) Remove the lampshade of rear indoor lamp assy. (Refer to “Chapter 64 lighting - rear indoor lamp assy,
replacement”)
(b) Remove the rear indoor lamp bulb.
3. INSTALL REAR INDOOR LAMP BULB.

(a) Install the rear indoor lamp bulb.
(b) Install the lampshade of rear indoor lamp assy. (Refer to

“Chapter 64 lighting - rear indoor lamp assy,
replacement”)
LIGHTING - STEP LAMP ASSY 64-43
STEP LAMP ASSY

REPLACEMENT
2. REMOVE STEP LAMP ASSY.
(a) Remove the sliding door step board cover assy RH. (Refer to “Chapter 88 exterior and interior trim -
step board, replacement”)
64
(b) Disconnect the connector of step lamp assy.
(c) Remove the step lamp assy.

64-44 LIGHTING - STEP LAMP ASSY
3. INSTALL STEP LAMP ASSY.

(a) Install the step lamp to the sliding door step board cover
assy RH and connect the connector of step lamp assy.
(b) Install the sliding door step board cover assy RH. (Refer
to “Chapter 88 exterior and interior trim - step board,
replacement”)
LIGHTING - STEP LAMP BULB 64-45
STEP LAMP BULB

REPLACEMENT
2. REMOVE LAMPSHADE.
(a) Use a screwdriver to remove the lampshade.
NOTE 64
3. REMOVE THE STEP LAMP BULB.
4. INSTALL THE STEP LAMP BULB.
5. INSTALL LAMPSHADE.

64-46 LIGHTING - HEADLAMP DIMMER SWITCH ASSY
HEADLAMP DIMMER SWITCH ASSY

REPLACEMENT
2. REMOVE HEADLAMP DIMMER SWITCH ASSY.
(a) Remove combination switch assy. (Refer to “Chapter 51 steering column - combination switch assy,
replacement”)
(b) Remove 2 screws from headlamp dimmer switch assy.
(c) Remove the headlamp dimmer switch assy.
3. INSTALL HEADLAMP DIMMER SWITCH ASSY.

(a) Install the headlamp dimmer switch assy with 2 screws.
(b) Install combination switch assy. (Refer to “Chapter 51

steering column - combination switch assy,
replacement”)
LIGHTING - REAR FOG LAMP SWITCH ASSY 64-47
REAR FOG LAMP SWITCH ASSY

REPLACEMENT
2. REMOVE REAR FOG LAMP SWITCH ASSY.
(a) Remove electric appliance switch panel LH. (Refer to “Chapter 83 instrument panel - dashboard,
replacement”)
64
(b) Remove the fog lamp switch assy.
3. INSTALL REAR FOG LAMP SWITCH ASSY.

(a) Install the rear fog lamp assy to electric appliance switch panel LH.
(b) Install electric appliance switch panel LH. (Refer to “Chapter 83 instrument panel - dashboard,
replacement”)
MEMO
WIPER AND WASHER
65
WIPER AND WASHER SYSTEM....................................................... 65-1
PRECAUTION.............................................................................. 65-1 65
COMPONENTS ........................................................................... 65-5
INSPECTION ............................................................................... 65-7
WIPER ASSY ................................................................................... 65-16
REPLACEMENT ........................................................................ 65-16
WIPER MOTOR ASSY ..................................................................... 65-21
REPLACEMENT ........................................................................ 65-21
WIPER LINK ASSY .......................................................................... 65-28
REPLACEMENT ........................................................................ 65-28
WIPER BLADE WITH BRACKET ASSY ......................................... 65-32
REPLACEMENT ........................................................................ 65-32
WASHER NOZZLE........................................................................... 65-33
INSPECTION ............................................................................. 65-33
ADJUSTMENT ........................................................................... 65-34
WIPER AND WASHER - WIPER AND WASHER SYSTEM 65-1
WIPER AND WASHER SYSTEM

WIPER AND WASHER
PRECAUTION
1. WIPER AND WASHER SYSTEM PRECAUTION. 65
(a) Usually use ordinary washer fluid for window glass.
(b) Sometimes use water instead of the washer fluid temporarily. 65
(c) Be sure to fill correct coolant in low temperature area.
(d) Never use the coolant for engine or other substitutes to prevent damage on body paint.
65-2 WIPER AND WASHER - WIPER AND WASHER SYSTEM

1. Fuse (Damaged) -
Chapter 65 wiper and washer - wiper and

washer system, inspection
2. Wiper switches (Damaged) Chapter 51 steering column - combination
switch assy, replacement
Wipers do not operate
3. Wiper motors (Damaged) Chapter 65 wiper and washer - wiper motor
assy, replacement

1. Front wiper switch (Damaged) Chapter 51 steering column - combination
Front wipers do not Chapter 65 wiper and washer - wiper and
operate in LO or HI washer system, inspection
2. Front wiper motor (Damaged) Chapter 65 wiper and washer - wiper motor
assy, replacement


Front wipers do not 2. Solid state timer (Damaged) Chapter 51 steering column - combination
operate in INT switch assy, replacement

3. Front wiper motor (Damaged) Chapter 65 wiper and washer - wiper motor
assy, replacement

1. Rear wiper and washer switch washer system, inspection
(Damaged) Chapter 51 steering column - combination
Rear wiper does not Chapter 65 wiper and washer - wiper and
operate washer system, inspection
2. Multi-function controller
(Damaged) Chapter 51 steering column - steering column
beam welding assy, replacement


Chapter 65 wiper and washer - wiper assy,
1. Wiper arms (Installed incorrectly) replacement
65
Wiper arms do not stop Chapter 65 wiper and washer - wiper and
automatically or not in washer system, inspection
correct position (Wiper 2. Wiper motors (Damaged) 65
Chapter 65 wiper and washer - wiper motor
switch turned off) assy, replacement
Chapter 65 wiper and washer - wiper link assy,

1. Worm (Rusty or unlubricated) replacement
Chapter 65 wiper and washer - wiper link assy,

Abnormal noise 2. Wiper link (Worn or deformed) replacement
3. Wiper blade assy (Aging or Chapter 65 wiper and washer - wiper blade
cracked) with bracket assy, replacement
1. Front and rear windshield (Be -

soiled by oil or wax)
2. Washer fluid (Poor quality) -
3. Wiper blade assy (Incorrect type) -
Wiper effect poor 4. Wiper blade assy (Aging or Chapter 65 wiper and washer - wiper blade
cracked) with bracket assy, replacement
5. Wiper arms (Deformed or Chapter 65 wiper and washer - wiper assy,

damaged) replacement
6. Wiper arms (Spring force Chapter 65 wiper and washer - wiper assy,
declined) replacement


2. Rear wiper and washer switch washer system, inspection
Washers do not operate
(Damaged) Chapter 51 steering column - combination
3. Washer motor with pump assy Chapter 65 wiper and washer - wiper and
(Damaged) washer system, inspection

1. Washer fluid (Low) -
2. Washer fluid (Frozen) -
3. Washer fluid hose (curving or -

Washer fluid does not
spray or spray jam)
powerlessly Chapter 65 wiper and washer - washer nozzle,
4. Washer nozzle (Blocking) inspection
5. Washer motor with pump assy Chapter 65 wiper and washer - wiper and
(Damaged) washer system, inspection
Chapter 65 wiper and washer - washer nozzle,

Incorrect point where
1. Washer nozzle (Adjustment inspection
washer fluid spray on
required) Chapter 65 wiper and washer - washer nozzle,
front / rear windshield
adjustment
COMPONENTS
THE VEHICLE WITHOUT REAR WIPER ASSY
65
65
1 Front Wiper Assy 6 Washer
2 Bolt 7 Cap
3 Bolt 8 Sealing Membrane Type Ⅰ

4 Washer Assy 9 Cap
5 Bolt
THE VEHICLE WITH REAR WIPER ASSY
1 Front Wiper Assy 6 Washer
2 Bolt 7 Rear Wiper Assy
3 Bolt 8 Bolt
4 Washer Assy 9 Lock Nut
5 Bolt
INSPECTION
1. INSPECT WASHER ASSY.
(a) Connect the battery positive terminal (+) to terminal 2 of 65
the washer motor with pump connector.
(b) Connect the battery negative terminal (-) to terminal 1 of 65
the washer motor with pump connector.
(c) Check that washer fluid pours out from the washer fluid
reservior.
If there is no washer fluid pours out from the reservior,
replace with a new washer assy.
CAUTION
Be sure to perform this operation in short time to prevent
washer assy damaged.
NOTE
• As shown in the illustration, front washer motor with
pump assy is the right one and rear washer motor
with pump assy (if equipped) is the left one.
• Fill the washer fluid if necessary.
2. INSPECT FRONT WIPER SWITCH AND FRONT

WASHER SWITCH.
(a) Check the resistance.
Standard:
Specified
Front wiper switch Terminal
condition
OFF 7 - 16 ＜2Ω
INT 7 - 16 ＜2Ω
LO 7 - 17 ＜2Ω
HI 8 - 17 ＜2Ω
Specified
Front washer switch Terminal
condition
OFF All ≥ 1 MΩ
ON 2 - 11 ＜2Ω
If the resistance is out of the specification, replace with a new

combination switch assy. (Refer to “Chapter 51 steering column
- combination switch assy, replacement”)
(b) Check the front wiper switch intermittent operation.

• Turn the front wiper switch to the “OFF” position.
• Connect the voltmeter positive terminal (+) to terminal 7

of the wiper and washer switch assy connector. Then
connect negative terminal (-) to terminal 2 of the
connector.
• Connect the battery positive terminal (+) to terminal 17 of
the wiper and washer switch assy connector. Then
connect negative terminal (-) to terminal 2 and 16 of the
connector.
• Turn the front wiper switch to the “INT” position.

the wiper and washer switch assy connector for 5
seconds.
• Connect the battery negative terminal (-) to terminal 16 of

the wiper and washer switch assy connector again to
activate the front wiper solid state timer relay.
65
65
• Measure the voltage between terminal 7 and 2 of the

wiper and washer switch assy.
Voltage: shown in the illustration
If the voltage is out of the specification, replace with a new

combination switch assy. (Refer to “Chpater 51 steering column
(c) Check the front washer switch operation.

• Turn the front washer switch to the “OFF” position.

the wiper and washer switch assy connector. Then
connect the negative terminal (-) to terminal 2 and 16 of
the connector.
of the wiper and washer switch assy connector. Then
connect positive terminal (+) to terminal 2 of the
connector.
• Turn the front washer switch to the “OFF” position

several seconds after turning it to the “ON” position.
• Measure the voltage between terminal 7 and 2 of the wiper
and washer switch assy.
If the voltage is out of the specification, replace with a new
3. INSPECT REAR WIPER AND WASHER SWITCH.

Standard:
Rear wiper and Specified

Terminal
washer switch condition
WASH1 2 - 12 ＜2Ω
OFF All ≥ 1 MΩ
INT 2 - 13 ＜2Ω
ON 2 - 10 ＜2Ω
WASH2 2 - 10 - 12 ＜2Ω
If the resistance is out of the specification, replace with a new

4. INSPECT MULTI-FUNCTION CONTROLLER (3-IN-1).

(a) Check the multi-function controller (3-in-1) wiper
operation.
of the multi-function controller (3-in-1) connector. Then
connect the negative terminal (-) to terminal 11 of the
connector.
the multi-function controller (3-in-1) connector. Then
connect the negative terminal (-) to terminal 11 and 14 to
the connector.

the multi-function controller (3-in-1) connector.
the multi-function controller (3-in-1) connector.

the multi-function controller (3-in-1) connector again to
activate the rear wiper intermittent relay.
65
65
• Measure the voltage between terminal 13 and 11 of the

multi-function controller (3-in-1) connector.
If the voltage is out of the specification, replace with a new multi-
function controller (3-in-1). (Refer to “Chapter 51 steering
column - steering column beam welding assy, replacement”)
5. INSPECT FRONT WIPER MOTOR ASSY.

(a) Check the front wiper motor operation at LO.
the front wiper motor assy connector and connect the
negative terminal (-) to terminal 5 of the connector to run
the motor at LO.
• Check the speed of front wiper motor running at LO.
Speed (LO): 40 ～ 50 r/min
If the speed is out of the specification, replace with a new front
wiper motor assy. (Refer to “Chapter 65 wiper and washer -
wiper motor assy, replacement”)
(b) Check the front wiper motor operation at HI.

the motor at HI.
• Check the speed of front wiper motor running at HI.
Speed (HI): 60 ～ 80 r/min
If the speed is out of the specification, replace with a new front
wiper motor assy. (Refer to “Chapter 65 wiper and washer -
wiper motor assy, replacement”)
(c) Check the automatic stop position of front wiper motor .

the motor at LO.
• Disconnect the battery positive terminal (+) from terminal

1 of the front wiper motor assy connector to stop the
motor at any position except the automatic stop position
specified.
• Connect terminal 1 and 2 of the front wiper motor assy

connector and connect the battery positive terminal (+) to
terminal 3 of the connector to run the motor again at LO.
65
65
• Check the automatic stop position of front wiper motor.

Standard: shown in the illustration
If the position is incorrect, replace with a new front wiper motor
assy. (Refer to “Chapter 65 wiper and washer - wiper motor
6. INSPECT REAR WIPER MOTOR WITH LINK ASSY.

(a) Check the rear wiper motor operation.
the rear wiper motor with link assy connector and
connector to run the motor.
• Check the speed of rear wiper motor.
Speed: 33 ～ 43 r/min
If the speed is out of the specification, replace with a new rear
wiper motor and link assy. (Refer to “Chapter 65 wiper and
washer - wiper motor assy, replacement”)
(b) Check the automatic stop position of rear wiper motor.

the rear wiper motor and link assy connector and
connector to run the motor .
• Disconnect the battery positive terminal (+) from terminal

4 of the rear wiper motor and link assy connector to stop
the motor at any position except the automatic stop
position specified.
• Connect the terminal 1 and 4 of the rear wiper motor and

link assy connector and connect the positive terminal (+)
to terminal 2 of the connector to run the motor again.
• Check the automatic stop position of rear wiper motor.

Standard: shown in the illustration
If the position is incorrect, replace with a new rear wiper motor
with link assy. (Refer to “Chapter 65 wiper and washer - wiper 65
motor assy, replacement”)
65
65-16 WIPER AND WASHER - WIPER ASSY
WIPER ASSY
REPLACEMENT
1. REMOVE FRONT WIPER ASSY LH.
(a) Turn the front wiper switch to the “INT / LO / HI” position to activate the front wiper assy.
CAUTION
Do not perform this operation when the windshield is dry to prevent scoring.
(b) Turn the front wiper switch to the “OFF” position to stop the front wiper assy at the automatic stop
position.
(c) Remove the front wiper arm cap.
(d) Loosen the nut and remove the spring washer.

WIPER AND WASHER - WIPER ASSY 65-17
(e) Remove the front wiper assy LH.

NOTE
Turn the front wiper arm LH up before performing this
operation. 65
65
2. REMOVE FRONT WIPER ASSY RH.

NOTE
3. REMOVE REAR WIPER ASSY.
(a) Turn the rear wiper switch to the “INT / ON” position to activate the rear wiper assy.
CAUTION
Do not perform this operation when the rear window is dry to prevent scoring.
(b) Turn the rear wiper switch to the “OFF” position to stop the rear wiper assy at the automatic stop
position.
(c) Remove the rear wiper arm cap.
(d) Loosen the nut.

(e) Remove the rear wiper assy.

NOTE
Turn the rear wiper arm up before performing this
operation.
4. INSTALL FRONT WIPER ASSY LH.

(a) Scrape off the serration part of the wiper arm with a
round file or equivalent.
(b) Clean the wiper pivot serration with the wire brush.
(c) Position the front wiper assy LH properly.

NOTE
• The front wiper blade assy LH should be located
along lower edge of the windshield.
• Turn the front wiper arm LH up before performing
this operation.
(d) Install the spring washer and tighten the nut.

WIPER AND WASHER - WIPER ASSY 65-19
(e) Install the front wiper arm cap.

NOTE
• Turn the front wiper arm LH down after performing 65
this operation.
• Make sure the front wiper blade assy LH is located 65
along lower edge of the rear windshield.
(f) Check the automatic stop position of front wiper assy LH.
• Turn the front wiper switch to the “INT / LO / HI” position
to activate the front wiper assy.
CAUTION
Do not perform this operation when the windshield is dry to
prevent scoring.
• Turn the front wiper switch to the “OFF” position to stop
the front wiper assy at the automatci stop position.
• Check whether the front wiper blade assy LH is located
along lower edge of the windshield.
5. INSTALL FRONT WIPER ASSY RH.

NOTE
6. INSTALL REAR WIPER ASSY.
(a) Scrape off the serration part of the wiper arm with a
round file or equivalent.
(b) Clean the wiper pivot serration with the wire brush.
(c) Position the rear wiper assy properly.

NOTE
• The rear wiper blade assy should be located along
the lower edge of the rear window.
• Turn the rear wiper arm up before performing this
operation.
(d) Tighten the nut.

(e) Install the rear wiper arm cap.

NOTE
• Turn the rear wiper arm down after performing this
operation.
• Make sure the rear wiper blade assy is located along
lower edge of the rear window.
(f) Check the automatic position of rear wiper assy.

• Turn the rear wiper switch to the “INT/ON” position to
activate the rear wiper assy.
CAUTION
• Turn the rear wiper switch to the “OFF” position to stop the rear wiper assy at the automatic stop
position.
• Check whether the rear wiper blade assy is located along lower edge of the rear window.
WIPER AND WASHER - WIPER MOTOR ASSY 65-21
WIPER MOTOR ASSY

REPLACEMENT
1. STOP WIPER ASSY AT AUTOMATIC STOP POSITION. 65
(a) Stop the front wiper assy at the automatic stop position.
• Turn the front wiper switch to the “INT / LO / HI” position to activate the front wiper assy. 65
CAUTION
• Turn the front wiper switch to the “OFF” position to stop the front wiper assy at the automatci stop
position.
(b) Stop the rear wiper assy at the automatic stop position.
• Turn the rear wiper switch to the “INT / ON” position to activate the rear wiper assy.
CAUTION
position.
3. REMOVE FRONT WIPER MOTOR ASSY.

(a) Open the engine hood and support it with the hood rod.
(b) Disconnect the front wiper motor assy connector.

65-22 WIPER AND WASHER - WIPER MOTOR ASSY
(c) Loosen 4 bolts.
(d) Seperate the front wiper motor assy from the front wiper
link assy.
(e) Remove the front wiper motor assy.
CAUTION
Store the front wiper motor assy carefully. Do not rotate the
rocker arm of front wiper motor assy.
4. REMOVE REAR WIPER MOTOR WITH LINK ASSY.

(a) Remove the rear wiper assy. (Refer to “Chapter 65 wiper and washer - wiper assy, replacement”)
(b) Remove the rear wiper cover.
(c) Loosen the nut.
(d) Remove the rear hatch lower inner guard board. (Refer
to “Chapter 88 exterior and interior trim - vehicle door
inner guard board, replacement”)
(e) Disconnect the rear wiper motor with link assy connector.
65
65
(f) Loosen the bolt.
(g) Disconnect the ground wire harness.
(h) Loosen 3 bolts.
(i) Turn the rear wiper motor with link assy over.
(j) Seperate the harness clamp from the plate.
(k) Remove the rear wiper motor with link assy.

CAUTION
Store the rear wiper motor with link assy carefully. Do not
rotate the rocker arm of rear wiper motor with link assy.
5. INSTALL FRONT WIPER MOTOR ASSY.

(a) Connect the front wiper motor assy to the front wiper link
assy.
NOTE
If hear a “click”, the front wiper motor assy is connected to
the front wiper link assy completely.
(c) Connect the front wiper motor assy connector.

6. INSTALL REAR WIPER MOTOR WITH LINK ASSY.

(a) Insert the harness clamp into the plate.
65
65
(b) Position the rear wiper motor with link assy properly.
NOTE
Align the rear wiper pivot with the mounting hole on rear
hatch.
(c) Tighten 3 bolts.
(d) Position the ground wire harness properly.

(e) Tighten the bolt.
(f) Connect the rear wiper motor with link assy connector.
(g) Install the rear hatch lower inner guard board. (Refer to
“Chapter 88 exterior and interior trim - vehicle door inner
(h) Tighten the nut.
(i) Install the rear wiper cover.
(j) Install the rear wiper assy. (Refer to “Chapter 65 wiper

and washer - wiper assy, replacement”)
replacement”).
8. CHECK AUTOMATIC STOP POSITION OF WIPER ASSY.
(a) Check automatic stop position of the front wiper assy LH. 65
• Turn the front wiper switch to the “INT / LO / HI” position to activate the front wiper assy.
65
CAUTION
• Turn the front wiper switch to the “OFF” position to stop the front wiper assy at the automatci stop
position.
• Check whether the front wiper blade assy LH is located along lower edge of the windshield.
(b) Check the automatic position of rear wiper assy.
• Turn the rear wiper switch to the “INT / ON” position to activate the rear wiper assy.
CAUTION
position.
• Check whether the rear wiper blade assy is located along lower edge of the rear window.
65-28 WIPER AND WASHER - WIPER LINK ASSY
WIPER LINK ASSY

REPLACEMENT
1. REMOVE FRONT WIPER LINK ASSY.
(a) Remove the front wiper assy. (Refer to “Chapter 65 wiper and washer - wiper assy, replacement”)
(b) Remove the rubber strip.
(c) Using a screwdriver, remove 9 clips.

NOTE
Never reuse the removed clip.
(d) Loosen 6 screws.
(e) Remove the cowl top grille.

WIPER AND WASHER - WIPER LINK ASSY 65-29
(f) Loosen 6 bolts.
65
65
(g) Remove the front wiper motor assy. (Refer to “Chapter

65 wiper and washer - wiper motor assy, replacement”)
(h) Pull out the front wiper link assy.
2. REMOVE REAR WIPER LINK ASSY.

(a) Remove the rear wiper motor with link assy. (Refer to “Chapter 65 wiper and washer - wiper motor assy,
replacement”)
3. INSTALL FRONT WIPER LINK ASSY.

(a) Insert the front wiper link assy.
65-30 WIPER AND WASHER - WIPER LINK ASSY
NOTE
Pull slightly the front wiper link assy out from the hole
which will be covered after performing the next operation.
(b) Install the front wiper motor assy. (Refer to “Chapter 65

wiper and washer - wiper motor assy, replacement”)
(c) Tighten 6 bolts.
(d) Position the cowl top grille properly.

WIPER AND WASHER - WIPER LINK ASSY 65-31
(e) Tighten 6 screws.
65
65
(f) Install 9 clips.

NOTE
Be sure to replace with new clips.
(g) Install the rubber strip.
(h) Install the front wiper assy. (Refer to “Chapter 65 wiper and
washer - wiper assy, replacement”)
4. INSTALL REAR WIPER LINK ASSY.

(a) Install the rear wiper motor with link assy. (Refer to “Chapter 55 wiper and washer - wiper motor assy,
replacement”)
65-32 WIPER AND WASHER - WIPER BLADE WITH BRACKET ASSY
WIPER BLADE WITH BRACKET ASSY

REPLACEMENT
1. REMOVE FRONT WIPER BLADE WITH BRACKET ASSY LH.
(a) Turn the front wiper blade bracket assy LH up.
(b) Press the latch plate, remove the front wiper blade with
bracket assy LH.
2. REMOVE FRONT WIPER BLADE WITH BRACKET ASSY RH.

NOTE
3. REMOVE REAR WIPER BLADE WITH BRACKET ASSY.
NOTE
Remove the rear by the same procedures as the front.
4. INSTALL FRONT WIPER BLADE WITH BRACKET

ASSY LH.
(a) Install the front wiper blade with bracket assy LH.
NOTE
If hear a “click”, the front wiper blade with bracket assy LH
is installed completely.
(b) Turn the front wiper blade bracket assy LH down.
5. INSTALL FRONT WIPER BLADE WITH BRACKET ASSY RH.

NOTE
6. INSTALL REAR WIPER BLADE WITH BRACKET ASSY.
NOTE
Install the rear by the same procedures as the front.
WIPER AND WASHER - WASHER NOZZLE 65-33
WASHER NOZZLE
INSPECTION
1. INSPECT WASHER NOZZLE. 65
(a) Turn the front washer switch to the “ON” position. Check the point which the washer fluid sprays on
windshield is within the range shown in the illustration. 65
(b) Turn the rear wiper and washer switch to the “WASH1 / WASH2” position. Check the point which the
washer fliuid sprays on rear window is within the range shown in the illustration.
65-34 WIPER AND WASHER - WASHER NOZZLE
ADJUSTMENT
1. ADJUST WASHER NOZZLE.
(a) Check the point which the washer fluid sprays on windshield and rear window. (Refer to “Chapter 65
wiper and washer - washer nozzle, inspection”)
(b) Insert a needle or equivalent into the nozzle to adjust until the point which the washer fluid sprays on
windshield and rear window is within the range specified.
AUDIO SYSTEM
66
AUDIO SYSTEM................................................................................. 66-1
COMPONENTS ........................................................................... 66-1
CD ASSY ............................................................................................ 66-2
REPLACEMENT .......................................................................... 66-2
FRONT SPEAKER ASSY LH............................................................. 66-6
REPLACEMENT .......................................................................... 66-6
REAR SPEAKER ASSY LH............................................................... 66-8
REPLACEMENT .......................................................................... 66-8
ANTENNA AMPLIFIER ASSY ......................................................... 66-10
REPLACEMENT ........................................................................ 66-10
ELECTRIC DEVICE ACCESSORIES .............................................. 66-12
COMPONENTS ......................................................................... 66-12
REPLACEMENT ........................................................................ 66-13
AUDIO SYSTEM - AUDIO SYSTEM 66-1
AUDIO SYSTEM
AUDIO SYSTEM
COMPONENTS
66
1 Front Speaker Assy LH 5 Rear Speaker Assy RH
2 Manual Antenna (Optional) 6 Antenna Amplifier Assy
3 CD/DVD Assy 7 Glass Amplifier Assy (Optional)
4 Front Speaker Assy RH 8 Rear Speaker Assy LH

66-2 AUDIO SYSTEM - CD ASSY
CD ASSY
REPLACEMENT

(a) Using a screwdriver, remove the middle panel assy.
NOTE
Be careful not to damage the middle panel assy and
dashboard. Tape the screwdriver tip before using it.
(b) Disconnect all the connectors from the middle panel

assy.

AUDIO SYSTEM - CD ASSY 66-3
3. REMOVE CD ASSY.
(a) Remove the 4 screws from CD assy.
66
(b) Take out CD assy and disconnect the connectors.
(c) Remove CD assy.

66-4 AUDIO SYSTEM - CD ASSY
4. INSTALL CD ASSY.
(a) Connect the connectors and install CD assy.

(a) Connect all connectors to the middle panel assy.
AUDIO SYSTEM - CD ASSY 66-5
(b) Install the middle panel assy.
66

7. INSPECT CD ASSY AND RESET THE STATIONS.
8. INSPECT WHETHER CD ASSY IS IN WORKING ORDER OR NOT.
66-6 AUDIO SYSTEM - FRONT SPEAKER ASSY LH
FRONT SPEAKER ASSY LH

REPLACEMENT
2. REMOVE FRONT DOOR INNER GUARD PLATE ASSY LH. (Refer to “Chapter 88 exterior and
interior trim - vehicle door inner guard board, replacement”)
3. REMOVE FRONT SPEAKER ASSY LH.

(a) Remove the 4 screws from front speaker assy LH.
(b) Remove the front speaker assy LH and disconnect the

connector.
(c) Remove the front speaker assy LH.

AUDIO SYSTEM - FRONT SPEAKER ASSY LH 66-7
4. INSTALL FRONT SPEAKER ASSY LH.

(a) Connect the connector and install the front speaker assy
LH.
66
(b) Install the front speaker assy LH and tighten 4 screws.
5. INSTALL FRONT DOOR INNER GUARD PLATE ASSY LH. (Refer to “Chapter 88 exterior and
interior trim - vehicle door inner guard board, replacement”)
7. INSTALL FRONT SPEAKER ASSY LH.
NOTE
66-8 AUDIO SYSTEM - REAR SPEAKER ASSY LH
REAR SPEAKER ASSY LH

REPLACEMENT
2. REMOVE SIDE WALL REAR LOWER GUARD BOARD LH. (Refer to “Chapter 88 exterior and
interior trim - side wall guard board, replacement”)
3. REMOVE REAR SPEAKER ASSY LH.

(a) Remove 4 screws from rear speaker assy LH.
(b) Disconnect the connector of the rear speaker assy LH.
(c) Remove the rear speaker assy LH.
4. INSTALL REAR SPEAKER ASSY LH.

(a) Connect the connector of the rear speaker assy LH.
AUDIO SYSTEM - REAR SPEAKER ASSY LH 66-9
(b) Install the rear speaker assy LH with 4 screws.
66
5. INSTALL SIDE WALL REAR LOWER GUARD BOARD LH. (Refer to “Chapter 88 exterior and
7. INSTALL REAR SPEAKER ASSY LH.
NOTE
66-10 AUDIO SYSTEM - ANTENNA AMPLIFIER ASSY
ANTENNA AMPLIFIER ASSY

REPLACEMENT
2. REMOVE D PILLAR UPPER INNER GUARD BOARD LH. (Refer to “Chapter 88 exterior and
3. REMOVE THE ANTENNA AMPLIFIER ASSY.

(a) Disconnect the connectors of the antenna amplifier.
(b) Remove antenna amplifier nuts.
(c) Remove the antenna amplifier assy.

AUDIO SYSTEM - ANTENNA AMPLIFIER ASSY 66-11
4. INSTALL THE ANTENNA AMPLIFIER.

(a) Connect the connectors of the antenna amplifier.
66
(b) Install the antenna amplifier with the nut.
5. INSTALL D PILLAR UPPER INNER GUARD BOARD LH. (Refer to “Chapter 88 exterior and
7. INSPECT THE ANTENNA AMPLIFIER ASSY AND RESET THE STATIONS.
66-12 AUDIO SYSTEM - ELECTRIC DEVICE ACCESSORIES
ELECTRIC DEVICE ACCESSORIES

COMPONENTS
1 Cigarette Lighter Assy 2 12 V Power Point Socket

AUDIO SYSTEM - ELECTRIC DEVICE ACCESSORIES 66-13
REPLACEMENT
2. REMOVE MIDDLE PANEL ASSY. (Refer to “Chapter 66 audio system - CD assy, replacement”)
66
3. REMOVE CIGARETTE LIGHTER ASSY.
4. REMOVE 12 V POWER POINT SOCKET ASSY.
5. INSTALL 12 V POWER POINT SOCKET ASSY.
6. INSTALL CIGARETTE LIGHTER.
7. INSTALL MIDDLE PANEL ASSY. (Refer to “Chapter 66 audio system - CD assy, replacement”)
9. INSPECT ELECTRIC DEVICE ACCESSORIES.
MEMO
WIRING
71
HOW TO USE THIS MANUAL ........................................................... 71-1
INTRODUCTION.......................................................................... 71-1
SYSTEM WIRING DIAGRAM SECTION EXAMPLE ................... 71-2
POWER SOURCE SECTION EXAMPLE .................................... 71-6
CONNECTOR VIEWS SECTION EXAMPLE .............................. 71-7
GLOSSARY OF TERMS AND SYMBOLS................................... 71-8
FUSE AND RELAY LOCATIONS .............................................. 71-10
WIRING DIAGRAM .......................................................................... 71-18
POWER SOURCE ..................................................................... 71-18
GROUND POINT ....................................................................... 71-24
ENGINE CONTROL SYSTEM ................................................... 71-29
COOLING FAN .......................................................................... 71-43
ANTI-LOCK BRAKE SYSTEM ................................................... 71-46
SUPPLEMENTAL RESTRAINT SYSTEM ................................. 71-52
INSTRUMENT CLUSTER.......................................................... 71-55
STARTING SYSTEM ................................................................. 71-69
CHARGING SYSTEM ................................................................ 71-73
LIGHTING SYSTEM .................................................................. 71-77
POWER DOOR LOCK ............................................................. 71-107
POWER WINDOW CONTROL ................................................ 71-120
HEATER AND AIR CONDITIONING CONTROL SYSTEM ..... 71-123
OUTSIDE MIRROR AND REAR WINDOW DEFROSTER ...... 71-147
COMMUNICATION SYSTEM .................................................. 71-153
POWER SOCKET.................................................................... 71-159
SLIDING ROOF ....................................................................... 71-161
IGNITION KEY POSITION REMIND CONTROLLER .............. 71-163
POWER MIRROR .................................................................... 71-165
WIPER AND WASHER ............................................................ 71-168
AUDIO...................................................................................... 71-171
CONNECTOR VIEWS .................................................................... 71-173
A - ENGINE ROOM WIRE HARNESS..................................... 71-173
B - FAN WIRE HARNESS........................................................ 71-178
C - INSTRUMENT PANEL WIRE HARNESS .......................... 71-179
D - REAR FOG LAMP WIRE HARNESS ................................. 71-203
E - ENGINE CONTROL WIRE HARNESS .............................. 71-204
F - ROOF WIRE HARNESS..................................................... 71-214
G - REAR BODY WIRE HARNESS RH ................................... 71-218
H - REAR BODY WIRE HARNESS LH.................................... 71-222
I - REAR HATCH WIRE HARNESS #1.................................... 71-225
J - REAR HATCH WIRE HARNESS #2 ................................... 71-226
K - CHASSIS WIRE HARNESS RH......................................... 71-227
L - CHASSIS WIRE HARNESS LH.......................................... 71-229
M - FRONT DOOR WIRE HARNESS RH................................ 71-231
N - FRONT DOOR WIRE HARNESS LH................................. 71-233
Q - FRONT BODY WIRE HARNESS....................................... 71-235
WIRE HARNESS & CONNECTOR LOCATION VIEWS ................ 71-242
A - ENGINE ROOM WIRE HARNESS..................................... 71-242
B - FAN WIRE HARNESS........................................................ 71-242
C - INSTRUMENT PANEL WIRE HARNESS
(INCLUDING DIAGNOSIS WIRE HARNESS & COMBINED
DISPLAY WIRE HARNESS) .................................................... 71-244
D - REAR FOG LAMP WIRE HARNESS ................................. 71-248
I - REAR HATCH WIRE HARNESS #1 .................................... 71-248
J - REAR HATCH WIRE HARNESS #2 ................................... 71-248
E - ENGINE CONTROL WIRE HARNESS
(WITH 4G63/4G64 ENGINE) .................................................. 71-250
(WITH BJ493ZQ3 ENGINE)..................................................... 71-252
E - ENGINE ROOM SUB-HARNESS....................................... 71-252
F - ROOF WIRE HARNESS..................................................... 71-254
L - CHASSIS WIRE HARNESS LH.......................................... 71-254
F - ROOF SUB-HARNESS
(REAR EVAPORATOR WIRE HARNESS) ............................. 71-256
G - REAR BODY WIRE HARNESS RH ................................... 71-257
H - REAR BODY WIRE HARNESS LH .................................... 71-257
K - CHASSIS WIRE HARNESS RH ......................................... 71-257
M - FRONT DOOR WIRE HARNESS RH ................................ 71-259
N - FRONT DOOR WIRE HARNESS LH ................................. 71-260
Q - FRONT BODY WIRE HARNESS....................................... 71-261
WIRING - HOW TO USE THIS MANUAL 71-1
HOW TO USE THIS MANUAL

WIRING
INTRODUCTION
This manual provides information on the electrical circuits installed on vehicles by dividing them into a circuit 71
for each system. The actual wiring of each system wiring diagram is shown from the point where the power
source is received from the battery as far as each ground point. (All wiring diagrams are shown with the 71
switches in the OFF position.)
When troubleshooting any problem, firstly, make sure you understand the operation of the circuit where the
problem was detected (see System Wiring Diagram Section). Secondly, understand the power source supply-
ing power to that circuit (see Power Source Section). Finally, understand the direction of current flow (see Sys-
tem Description).
When the circuit operation is understood, begin troubleshooting of the problem circuit to find out the cause.
(Based on relays, controllers, accessory, inlines, sensors, actuators, switches, ground points, connection loca-
tion of each system wiring diagram and wire harness location.)
71-2 WIRING - HOW TO USE THIS MANUAL
SYSTEM WIRING DIAGRAM SECTION EXAMPLE
*The system wiring diagram shown here is an EXAMPLE ONLY. It is different to the actual circuit
shown in the SYSTEM WIRING DIAGRAM SECTION.
Note
No. Name Description

1 System Title Distinguish between different systems and functions, easy to query. 71
Wire colors are indicated by an alphabetical code.
B=Black O=Orange V=Violet BR=Brown 71
G=Green P=Pink W= White GR=Gray
L =Blue R=Red Y=Yellow LG=Light Green
2 Indicates the wire color The first letter indicates the basic wire color and the second letter indicates
the color of the stripe.
Example:
R (Red)
L-B (Blue and Black)
Indicates the Name of electrical component, easy to query.

3
component name An electrical component can only have one name.
Indicates the Number of electrical component, easy to query.

4
component number An electrical component has one or more number.
Female and male connectors have different numbering rules.

The two examples below are viewed from terminal side when connectors are
unplugged.
Female - Numbered in order from upper right to lower left.
Indicates the pin

5
number of connector
Male - Numbered in order from upper left to lover right
This rules also applied to inline connector numbering.

The first letter of the code for each ground point(s) indicates the component’s
6 Indicates a ground point
location.
Indicates related Indicate that other system(s) associated with this system.
7
system
Indicates inline A group of inline has two connector numbers, one is the female and the other
8
connector number is the male.
Male:
Indicates inline
9
gender Female:
Note

10 System Description Describe the current flows and how the system works. 71
11 Service Hints Describe the component's value and principle. Refer in the service process.
71
12 Parts Location Indicate the wire harness showing the parts location on the vehicle.
13 Inline Indicate the inline two parts gender and the connected wire harness types.
14 Ground Points Indicate the ground location of each wire harness.

POWER SOURCE SECTION EXAMPLE

The “POWER SOURCE” section, describes how the current flows and each part power feed conditions. In the
POWER SOURCE wiring diagram, the conditions when battery power is supplied to each system are explained.
Since all system wiring diagrams start from the power source, the power source system must be fully
understood.
CONNECTOR VIEWS SECTION EXAMPLE
71
71
*The connector views shown here is an EXAMPLE ONLY. It is different to the actual connector views
shown in the CONNECTOR VIEWS SECTION.
Note

1 Connector Face Indicate connector face and pin order.
Name of electrical component, easy to query.

2 Component Name
An electrical component can only have one name.
Number of electrical component, easy to query.

3 Component Number
An electrical component has one or more number.
4 Connector Information Indicate pin number, wire color and function.

GLOSSARY OF TERMS AND SYMBOLS

BATTERY
Stores chemical energy and converts it into electrical energy.
Provides DC current for the auto’s various electrical circuits.
GROUND
The point at which wiring attaches to the body, thereby providing a
return path for an electrical circuit. Without a ground, current cannot
flow.
FUSIBLE LINK FUSIBLE LINK

A heavy–gauge wire placed in high amperage a circuit which burns
through on overloads, thereby protecting the circuit.
The numbers indicate the cross section surface area of the wires.
FUSE FUSE
A thin metal strip which burns through when too much current flows
through it, thereby stopping current flow and protecting a circuit from
damage.
COIL
When the magnetic field engenders fluctuations, the coil circuit is
induced electromotive force.
SOLENOID
An electromagnetic coil which forms a magnetic field when current
flows, to move a plunger, etc.
SINGLE FILAMENT LAMPS

Current flow causes a headlight filament to heat up and emit light. A
headlight may have either a single filament or a double filament.
DOUBLE FILAMENT
MOTOR MOTOR
A power unit which converts electrical energy into mechanical
energy, especially rotary motion.
SPEED MOTOR
INLINE
Indicate the connector joining wire harness and wire harness.
DIODE
A semiconductor which allows current flow in only one direction.
LED (LIGHT EMITTING DIODE)

Upon current flow, these diodes emit light without producing the
heat of a comparable light.
HORN
An electric device which sounds a loud audible signal.
SPEAKER
An electromechanical device which creates sound waves from
current flow.
RESISTOR RESISTOR
An electrical component with a fixed resistance, placed in a circuit to
reduce voltage to a specific value.
71
TAPPED RESISTOR TAPPED RESISTOR
A resistor which supplies two or more different non adjustable 71
resistance values.
SLIDE RHEOSTAT SLIDE RHEOSTAT

A controllable resistor with a variable rate of resistance. Also called
a potentiometer or rheostat.
THERMISTOR SENSOR
A resistor which varies its resistance with temperature.
POWER SOCKET (CIGARETTE LIGHTER)

An electric resistance heating element.
MANUAL SWITCH
Opens and closes circuits, thereby stopping or allowing current flow.
IGNITION SWITCH
A key operated switch with several positions which allows various
circuits, particularly the primary ignition circuit, to become
operational.
HEATER
An electric resistance heating element.
CLOCK SPRING
Used to connect the driver airbag. The normal rotation process to
ensure the electrical connections.
RELAY
Basically, an electrically operated switch which may be normally
closed or open. Current flow through a small coil creates a magnetic
field which either opens or closes an attached switch.
FUSE AND RELAY LOCATIONS

ENGINE ROOM JUNCTION BOX LOCATION - WITH 4G63/4G64 ENGINE
FUSIBLE LINK
Fuse Fuse
Code Name Code Name
Amp Amp
FL0 120A ALT Fusible Link FL4 20A Power Window Fusible Link
FL1 60A AM1 Fusible Link FL5 30A Rear Evaporator Fusible Link
FL2 40A Front Heater Fusible Link FL6 30A Defrost Fusible Link
FL3 50A Headlamp Fusible Link

FUSE
71
71
Fuse Fuse
Code Name Code Name
Amp Amp
F21 20A EFI Fuse F25 15A Hazard Lamp Fuse
F22 15A Front Fog Lamp Fuse F26 7.5A Memory Fuse
F23 15A Rear Fog Lamp Fuse F27 15A Stop Lamp Fuse
F24 20A AM2 Fuse
RELAY
Code Name
R5 Starter Relay
RELAY
Code Name Code Name

R1 Fuel Pump Relay R6 Horn Relay
R2 Main Relay R7 Front Fog Lamp Relay
R4 Parking Lamp Relay
RELAY
Code Name
R3 Headlamp Relay
ENGINE ROOM JUNCTION BOX LOCATION - WITH BJ493ZQ3 ENGINE
FUSIBLE LINK
Fuse Fuse
Code Name Code Name
Amp Amp
FL0 120A ALT Fusible Link FL4 20A Power Window Fusible Link
FL1 60A Preheat Fusible Link FL5 30A Rear Evaporator Fusible Link
FL2 40A Front Heater Fusible Link FL6 50A AM1 Fusible Link
FL3 50A Headlamp Fusible Link

FUSE
71
71
Fuse Fuse
Code Name Code Name
Amp Amp
F21 25A Heater Fuse F25 15A Hazard Lamp Fuse
F22 15A Front Fog Lamp Fuse F26 7.5A Memory Fuse
F23 15A Rear Fog Lamp Fuse F27 20A Defrost Fuse
F24 20A AM2 Fuse
RELAY
Code Name
R5 Starter Relay
RELAY
Code Name Code Name

R1 Heater Relay R6 Horn Relay
R2 Main Relay R7 Front Fog Lamp Relay
R4 Parking Lamp Relay
RELAY
Code Name
R3 Headlamp Relay
BODY JUNCTION BOX - WITH 4G63/4G64 ENGINE
FUSE
Fuse Fuse
Code Name Code Name
Amp Amp
F1 15A Instrument Cluster Fuse F8 7.5A Diagnosis Fuse
F2 15A A/C Fuse F9 30A ABS Solenoid Valve Fuse
F3 5A ABS Fuse F10 30A ABS Actuator Fuse
F4 20A Wiper Fuse F11 15A Front Headlamp LH Fuse
F5 10A Turn Signal Lamp Fuse F12 15A Front Headlamp RH Fuse
F6 20A Sliding Roof Fuse F13 10A Interior Lamp Fuse
F7 15A Rear Heater Fuse F14 10A Audio Fuse

Fuse Fuse
Code Name Code Name
Amp Amp
F15 15A Cigarette Lighter Fuse F20 20A Defrost Fuse 71
F16 7.5A Starter Fuse F23 7.5A Not Used (Spare)
71
F17 7.5A IG Fuse F24 20A Not Used (Spare)
F18 7.5A Parking Lamp Fuse F25 30A Not Used (Spare)
F19 7.5A Illumination Fuse
RELAY
Code Name Code Name

R9 Rear Heater Relay 2 R11 Front Heater Relay
RELAY
Code Name Code Name

R8 Defrost Relay R10 Rear Heater Relay 1
BODY JUNCTION BOX - WITH BJ493ZQ3 ENGINE
FUSE
Fuse Fuse
Code Name Code Name
Amp Amp
F1 15A Instrument Cluster Fuse F8 7.5A Diagnosis Fuse
F2 15A A/C Fuse F9 30A ABS Solenoid Valve Fuse
F3 5A ABS Fuse F10 30A ABS Actuator Fuse
F4 20A Wiper Fuse F11 15A Front Headlamp LH Fuse
F5 10A Turn Signal Lamp Fuse F12 15A Front Headlamp RH Fuse
F6 20A Sliding Roof Fuse F13 10A Interior Lamp Fuse
F7 15A Rear Heater Fuse F14 10A Audio Fuse

Fuse Fuse
Code Name Code Name
Amp Amp
F15 15A Cigarette Lighter Fuse F21 10A ECM Fuse 71
F16 7.5A Starter Fuse F22 15A ECM Fuse
71
F17 10A Mass Air Flow Fuse F23 7.5A Not Used (Spare)
F18 7.5A Parking Lamp Fuse F24 20A Not Used (Spare)
F19 7.5A Illumination Fuse F25 30A Not Used (Spare)
F20 20A Oil Water Separator Fuse
RELAY
Code Name Code Name

R9 Rear Heater Relay 2 R11 Front Heater Relay
RELAY
Code Name Code Name

R8 Defrost Relay R10 Rear Heater Relay 1
71-18 WIRING - WIRING DIAGRAM
WIRING DIAGRAM
POWER SOURCE
POWER SOURCE - WITH 4G63/4G64 ENGINE
WIRING - WIRING DIAGRAM 71-19
71
71
Service Hints
• C033 Ignition Switch
AM1 - ACC: Closed with the ignition switch at ACC/ON position.
AM1 - IG1: Closed with the ignition switch at ON/ST position.
AM2 - ST2: Closed with the ignition switch at ST position.
Parts Location
Code Wire Harness

C033 Instrument Panel Wire Harness
Connector Joining Wire Harness and Wire Harness
Code Code Wire Harness (Connector Location)

Engine Room Wire Harness & Instrument Panel Wire Harness
A101 C106
(Left Side of the Instrument Panel)

A102 C108

A104 C107
Ground Points
Code Ground Points Location Code Ground Points Location

A202 Left Side of the Engine Room C211 Left Side of the Instrument Panel
POWER SOURCE - WITH BJ493ZQ3 ENGINE
71
71
Service Hints
AM1 - ACC: Closed with the ignition switch at ACC/ON position. 71
AM2 - ST2: Closed with the ignition switch at ST position. 71
Parts Location
Code Wire Harness


A101 C106

A102 C108

A104 C107
Ground Points

GROUND POINT
71
71

71
Engine Room Wire Harness & Fan Wire Harness
A103 B101
(Between Front Combination Lamp LH and Main Fan Motor)
71
Instrument Panel Wire Harness & Chassis Wire Harness LH
C101 L101
(Under Left Side of the Instrument Panel)
Instrument Panel Wire Harness & Diagnosis Wire Harness

C109 C701
(Inside Steering Column Lower Cover, on the Left Side of the Instrument Panel)
Instrument Panel Wire Harness & Front Door Wire Harness RH

C114 M102
(Inside Front Fender RH)
Instrument Panel Wire Harness & Front Body Wire Harness

C115 Q103
(Inside Middle Panel) - with 4G63/4G64 Engine

C116 Q104
Instrument Panel Wire Harness & Combined Display Wire Harness

C118 C501
(Inside Middle Air Vent)
Instrument Panel Wire Harness & Front Door Wire Harness LH

C120 N103
(Inside Front Fender LH)

C122 Q107
(Inside Middle Panel) - with BJ493ZQ3 Engine
Roof Wire Harness & Rear Evaporator Wire Harness

F105 F401
(B-Pillar RH, near Roof)
Rear Body Wire Harness RH & Chassis Wire Harness RH

G103 K101
(Front Door Step Board RH)
Rear Body Wire Harness RH & Rear Body Wire Harness LH

G104 H101
(D-Pillar RH, near Floor)
Rear Body Wire Harness LH & Rear Fog Lamp Wire Harness
H102 D101
(D-Pillar LH, near Floor)
Rear Hatch Wire Harness #1 & Roof Wire Harness

I101 F104
(D-Pillar RH, near Roof)
Rear Hatch Wire Harness #1 & Rear Hatch Wire Harness #2

I103 J101
(Sliding Door LH)
Front Body Wire Harness & Rear Body Wire Harness RH

Q101 G102
(Sliding Door Step Board RH)
Front Body Wire Harness & Instrument Panel Wire Harness

Q106 C121
Ground Points

A201 Left Side of the Engine Room C243 Right Side of the Instrument Panel
A203 Right Side of the Engine Room C245 Left Side of the Washer Pump
A204 Right Side of the Engine Room C246 Right Side of the Instrument Panel
C210 Left Side of the Instrument Panel E201 Transmission Holder
C211 Left Side of the Instrument Panel F205 Above Rear Window RH
C213 Left Side of the Instrument Panel G201 Above Rear Wheelhouse RH
C214 Right Side of the Instrument Panel H201 Above Rear Wheelhouse LH
C242 Right Side of the Instrument Panel J220 Under Rear Wiper Motor
ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM - WITH 4G63/4G64 ENGINE
71
71
71
71
System Description
Engine control system of 4G63 and 4G64 engine is based on Engine Control Module (ECM) of Delphi
MT20U2 as the center system. The engine control system mainly consists of sensor signal input, engine con- 71
trol module (ECM) and executive control.
71
• Sensor Signal Input
Manifold Absolute Pressure/Intake Air Temperature (MAP/IAT) Sensor
Manifold absolute pressure/intake air temperature (MAP/IAT) sensor integrates functions of manifold absolute
pressure sensor with those of intake air temperature sensor, while achieving the functions of feedback
manifold absolute pressure and intake air temperature.
Manifold absolute pressure sensor measures engine inhaled air volume, which is a critical element that forms
method of speed-density type air flow measurement. The sensor directly senses manifold absolute pressure
state inside the engine intake manifold. The engine control module (ECM) takes this reference signal as the
basis to adjust the basic fuel supply sprayed into the engine.
Intake air temperature sensor uses NTC (negative temperature coefficient) thermistor sensor, with which the
engine control module (ECM) measures the air temperature in the engine cylinder and modifies the engine
fuel supply.
Mounting Position: on the intake manifold pipe of the engine fourth-cylinder.
Engine Coolant Temperature Sensor

Engine coolant temperature sensor is used for detecting engine operating temperature. The engine control
module (ECM) provides the optimum control solution for the engine according to different temperatures.
Engine coolant temperature sensor uses NTC thermistor sensor, with engine coolant temperature rising and
resistance value decreasing.
Mounting Position: on the engine main waterways.
Crankshaft Position Sensor

As magnetoelectric sensor, crankshaft position sensor works with gear ring of crankshaft. The sensor detects
the change of reluctance while the crankshaft rotates and alternating reluctance generates alternating output
signal. The notch positions on the gear ring correspond to top dead center (TDC) in the engine. The engine
control module (ECM) uses this signal to determine the rotation position and speed of the crankshaft.
Mounting Position: on the flywheel housing perpendicular to the crankshaft position.
Knock Sensor
Knock sensor is a vibration acceleration sensor, equipped at the engine knock induction-sensitive parts and
used for sensing the knock generated by the engine. The engine control module (ECM) uses knock intensity
detected by the knock sensor to modify ignition advance angle and achieve the effective control of the knock,
so as to optimize engine power performance, fuel economy and reduce emissions.
Mounting Position: between Cylinders 2 and 3 of the engine block.
Throttle Position Sensor

Throttle position sensor consists of carbon film resistor and sliding pointer driven by throttle shaft. When the
throttle opening changes, the signal that the sensor feeds back to the engine control module (ECM) also
varies. The control module determines real-time engine load and dynamic change condition based on the
sensor signal value and its rate of change.
Mounting Position: on the throttle body assembly, coaxial with the throttle lever and throttle.
Upstream (Downstream) Oxygen Sensor

Oxygen sensor is an important symbolic component of closed loop fuel control system. With its adjustment
and keeping the desired air-fuel ratio, the three-way catalytic converter can
achieve the best conversion efficiency. The zirconium oxide in oxygen sensor is heated (> 300 ℃ ) for
activation. The sensor changes the output voltage according to the presence or absence of oxygen in the
exhaust and determines the oxygen content in the exhaust. If the oxygen content in the exhaust is increased,
output voltage of oxygen sensor will be decreased; on the other hand, the output voltage will be increased,
thus providing feedback of the actual air-fuel ratio conditions for the engine control module (ECM). Usually,
when the sensor has the theoretical air-fuel ratio (14.6:1), it will result in dramatic change of voltage amplitude,
helping the engine control module (ECM) to accurately determine the air-fuel ratio.
Mounting Position: The upstream oxygen sensor is mounted in front of three-way catalytic converter of the
engine exhaust pipe; and the downstream oxygen sensor is mounted behind the three-way catalytic converter.
Odometer Sensor
Odometer sensor is Hall effect sensor, working with signal wheel on the transmission output shaft. The engine
control module (ECM) measures digital voltage signal through the sensor. In order to determine the current
vehicle speed.
Mounting Position: On the transmission output shaft end.
• Executive Control
Fuel injection Control
The system uses the speed density method to make multi-point sequential injection, i.e., each engine cycle
implements accurate fuel supply through main pulse width and amended pulse width, which has closed-loop
control and self-learning function.
Oil pump is single-stage electric turbine pump, and its operation is controlled by the engine control module
(ECM) through the pump relay. When ignition switch is turned on, the pump will run for 1.5 seconds. If the
crankshaft position signal is not received, the pump will stop running. If the crankshaft position signal is
detected, the oil pump starts to work. Upon loss of crankshaft position signal, the pump will stop running.
Mounting Position: in the fuel tank.
Fuel injector is a ball valve device with solenoid switch. The coil in injector is controlled grounded by the
engine control module (ECM) to produce magnetic force and pull up spool. The fuel is ejected from the pilot
hole in the form of mist. The main factors affecting changes in fuel injection pulse width include air-fuel ratio,
manifold absolute pressure, intake air temperature, closed loop feedback correction, acceleration
concentration, deceleration cutoff, self-learning and correction.
Mounting Position: Fixed on the intake manifold through the fuel rail.
Ignition Control
The system uses grouping ignition. Ignition coil is divided into two groups, each group providing the ignition
energy for two cylinder spark plugs with 360-degree crankshaft angle difference.
Mounting Position: Above the timing belt casing.
Idle Control
The system uses the idle air control, achieving high-precision idle speed control.
The idle stepping motor controls circulation area of throttle body bypass air duct to adjust control volume in the
engine. The engine control module (ECM) controls the amount of movement (forward / backward) for the
stepping motor through the digital square wave signal.
Mounting Position: On the throttle body assembly.
Canister Solenoid Valve Control
The engine control module (ECM) controls volume of gasoline vapor in intake manifold flowing from canister
through the canister solenoid valve control. The opening of canister solenoid valve is determined by the
engine control module (ECM) according to the duty cycle signal based on the state of engine.
Mounting Position: Between canister and intake manifold.
Fan Control
The engine control module (ECM) monitors the level of coolant temperature and whether the air-conditioning
works properly to determine the operating state of each fan.
• Malfunciton Diagnosis Function

When the system comes into operation, the engine control module (ECM) controls the operation of all parts of
the system and conducts detection in real time. Once the system or parts have faults, the system will switch on
the malfunction indicator light (MIL) to remind drivers of repair in time. When the system is in failure, the
engine control module (ECM) will start backup emergency control program.
Service Hints
• E002 Fuel Injector 1, E003 Fuel Injector 2, E004 Fuel Injector 3, E005 Fuel Injector 4
1 - 2: Approx. 12 Ω
1 - Ground: Approx. 12 volts
• E007 Throttle Position Sensor
• E009 Idle Air Control
1 - 2: Approx. 53 Ω
3 - 4: Approx. 53 Ω
• E010 Manifold Absolute Pressure/Intake Air Temperature (MAP/IAT) Sensor
• E017 Upstream Oxygen Sensor, E015 Downstream Oxygen Sensor 71
• E021 Engine Coolant Temperature Sensor
71
1 - 2: Approx. 29 KΩ (-20 ℃ )
Approx. 9 KΩ (0 ℃ )
Approx. 3 KΩ (20 ℃ )
Approx. 0.3 KΩ (80 ℃ )
Parts Location
Code Wire Harness Code Wire Harness

A012 Engine Room Wire Harness E006 Engine Control Wire Harness
B001 Fan Wire Harness E008 Engine Control Wire Harness
C008 Instrument Panel Wire Harness E013 Engine Control Wire Harness
C601 Diagnosis Wire Harness E020 Engine Control Wire Harness
E002 Engine Control Wire Harness E021 Engine Control Wire Harness
E003 Engine Control Wire Harness E023 Engine Control Wire Harness
E004 Engine Control Wire Harness L004 Chassis Wire Harness LH
E005 Engine Control Wire Harness L005 Chassis Wire Harness LH


A101 C106
(Left Side of The Instrument Panel)

A103 B101

A104 C107

C101 L101

C109 C701
Engine Control Wire Harness & Instrument Panel Wire Harness

E102 C102
(Under Clutch Pedal, on the Left Side of the Instrument Panel)

E103 C103
Ground Points

A203 Right Side of the Engine Room E201 Transmission Holder

ENGINE CONTROL SYSTEM - WITH BJ493ZQ3 ENGINE
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System Description
Engine control system of BJ493ZQ3 engine is based on Engine Control Module (ECM) of BOSCH as the
center system. The engine control system mainly consists of sensor signal input, engine control module (ECM)
and executive control.
• Sensor Signal Input

Mass Air Flow Sensor
Mass air flow sensor is a sensor to measure the air flow that the engine inhales. For the optimum engine fuel
injection quantity under all operating conditions, inhaled air flow will be converted to electrical signals which
are transmitted to the engine control module (ECM) and considered as one of basic signals that determine the
fuel injection quantity.
Mounting Position: on the hose between air filter and the turbocharger.
Engine Coolant Temperature Sensor

Engine coolant temperature sensor is used for detecting engine operating temperature. The engine control
module (ECM) provides the optimum control solution for the engine according to different temperatures.
Engine coolant temperature sensor uses NTC thermistor sensor, with engine coolant temperature rising and
resistance value decreasing.
Mounting Position: on the engine main waterways.
Crankshaft Position Sensor

As magnetoelectric sensor, crankshaft position sensor works with gear ring of crankshaft. The sensor detects
the change of reluctance while the crankshaft rotates and alternating reluctance generates alternating output
signal. The notch positions on the gear ring correspond to top dead center (TDC) in the engine. The engine
control module (ECM) uses this signal to determine the rotation position and speed of the crankshaft.
Mounting Position: on the flywheel housing perpendicular to the crankshaft position.
Accelerator Pedal Position Sensor

Accelerator pedal position sensor detects the position of accelerator pedal. When it detects the change of
accelerator pedal position, the change information will be transmitted instantaneously to the engine control
module (ECM), which will carry out operation processing for the information, as one of basic signals for
adjustment of fuel injection quantity.
Mounting Position: at the accelerator pedal.
Odometer Sensor
Odometer sensor is Hall effect sensor, working with signal wheel on the transmission output shaft. The engine
control module (ECM) measures digital voltage signal through the sensor. In order to determine the current
vehicle speed.
Mounting Position: on the transmission output shaft end.
Camshaft Position Sensor

Camshaft position sensor collects position signal of valve camshaft and transmits the signal to the engine
control module (ECM), which identifies top dead centre of 1st cylinder compression through the signal,
carrying out fuel injection timing control.
Mounting Position: above the crankshaft belt pulley.
Common Rail Pressure Sensor

Common rail pressure sensor detects fuel pressure and converts fuel pressure into electrical signals, which
will be transmitted to the engine control module (ECM). The engine control module (ECM) adjusts the fuel
supply through the signal, adjust the common rail pressure.
Mounting Position: at the end of high-pressure common rail fuel pipe, close to the 4th cylinder.
• Executive Control
High Pressure Pump Solenoid Control Valve
With High Pressure Pump Solenoid Control Valve, fuel pressure in common rail pipeline can be adjusted to
optimize engine performance according to engine load conditions and economics and emissions
requirements.
Mounting Position: on the high pressure pump housing.
Fuel Injector
Fuel injector is a ball valve device with solenoid switch. The coil in injector is controlled grounded by the
engine control module (ECM) to produce magnetic force and pull up spool. The fuel is ejected from the pilot 71
hole in the form of mist.
Mounting Position: on the cylinder head. 71
EGR Valve
The engine control module (ECM) controls EGR valve to open timely according to engine speed, load, and
temperature, air flow and etc. A small amount of exhaust gas flows into the intake manifold for recycling
combustion.
Mounting Position: above the exhaust pipe.

When the system comes into operation, the engine control module (ECM) controls the operation of all parts of
the system and conducts detection in real time. Once the system or parts have faults, the system will switch on
the malfunction indicator light (MIL) to remind drivers of repair in time. When the system is in failure, the
engine control module (ECM) will start backup emergency control program.
Parts Location

C601 Diagnosis Wire Harness E050 Engine Control Wire Harness
E025 Engine Control Wire Harness K005 Chassis Wire Harness RH
E026 Engine Control Wire Harness Q010 Front Body Wire Harness

A102 C108

A104 C107

C122 Q107

E106 C123
(Under A-Pillar, on the Left Side of the Instrument Panel) - with BJ493ZQ3 Engine

G103 K101

Q101 G102

Q106 C121
Ground Points

COOLING FAN
COOLING FAN - WITH BJ493ZQ3 ENGINE
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System Description
The current flows through fusible link FL6 in engine room junction box, to pin 5 of cooling fan control module.
System is then powered.
When ignition switch is ON/ST, the current pass through pin 4 of cooling fan control module, and emit the igni-
tion signal to the cooling fan control module.
Signal Input
The current flows from pin 2 of cooling fan control module, to pin 1 of cooling fan temperature sensor, pin 2 of
cooling fan temperature sensor, pin 1 of cooling fan control module, and emit the coolant temperature signal to
the cooling fan control module.
The current flows from pin 6 of cooling fan control module, to pin 10 of A/C amplifier. This identified if the A/C
operated or not.
The current flows from pin 7 of cooling fan control module, to pin 1 of dual function pressure switch. The power
is ground at pin 3 of dual function pressure switch. This identified if the A/C pressure is normal or not.
Cooling Fan Control (LO)

The current flows through fuse F29 in fan junction box, and pin 85 and pin 87 of main fan relay (LO) R13. The
current pass through pin 9 of cooling fan control module, and coil of main fan relay (LO) R13. Coil then creates
a magnetic field, and switch is activated. The current flows from pin 30 of main fan relay (LO) R13, to pin 30 of
main fan relay (HI) R14, and then pass from pin 87a of main fan relay (HI) R14, to pin 2 of main fan motor. The
power is ground at pin 3 of main fan motor. This enables main fan motor to operate at low speed.
Cooling Fan Control (HI)

The current flows through fuse F29 in fan junction box, to pin 85 and pin 87 of main fan relay (LO) R13, and
pin 85 of main fan relay (HI) R14 ; The current pass through pin 9 of cooling fan control module, to coil of main
fan relay (LO) R13. Coil then creates a magnetic field, and switch is activated. The current flows from pin 30 of
main fan relay (LO) R13, to pin 30 of main fan relay (HI) R14. The current pass through pin 8 of cooling fan
control module, and coil of main fan relay (HI) R14. Coil then creates a magnetic field, and switch is activated.
The current flows from pin 87 of main fan relay (HI) R14, to pin 1 of main fan motor. The power is ground at pin
3 of main fan motor. This enables main fan motor to operate at high speed.
The current flows through fuse F28 in fan junction box, to pin 85 and pin 87 of secondary fan relay R12. The
current pass through pin 8 of cooling fan control module, and coil of secondary fan relay R12. Coil then creates
a magnetic field, and switch is activated. The current flows through pin 1 of secondary fan motor. The power is
ground at pin 2 of secondary fan motor. This enables secondary fan motor to operate.
Service Hints
• A012 Dual Function Pressure Switch
1 - 3: Closed with the A/C pressure in normal.
Parts Location

A012 Engine Room Wire Harness B301 Fan Wire Harness
A301 Engine Room Wire Harness C008 Instrument Panel Wire Harness
B001 Fan Wire Harness C054 Instrument Panel Wire Harness


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A101 C106
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A102 C108

A103 B101

E106 C123
Ground Points

A203 Right Side of the Engine Room

ANTI-LOCK BRAKE SYSTEM

ANTI-LOCK BRAKE SYSTEM - WITH 4G63/4G64 ENGINE
System Description
Anti-lock braking system (ABS) uses wheel speed sensor to detect wheel speed and transmits the wheel
speed signal to the control module. The control module controls wheel slipping rate by repeatedly increasing 71
or decreasing the wheel brake pressure according to the input wheel speed, keep the wheels rotating. The
system enables the vehicle in braking state to prevent the wheels locking and have the steering capability, 71
guaranteeing stability in the braking direction and preventing side-slipping and deviation.
• Signal Input
The current flows through fuse F9 and fuse F10 in body junction box, to pin 9 and pin 25 of ABS module. ABS
actuator and solenoid valve are then powered.
When ignition switch is ON/ST, the current flows through fuse F3 in body junction box, to pin 4 of ABS module,
and to emit the ignition signal to the ABS module.
Speen Sensor Signal

The speed of the wheels is detected and input by front wheel speed sensor LH, front wheel speed sensor RH,
rear wheel speed sensor LH and rear wheel speed sensor RH.
Brake Signal
The current flows through fuse F27 in engine room junction box, to pin 2 of stop lamp switch. When the brake
pedal is depressed, the current flows from pin 1 of stop lamp switch, to pin18 of ABS module, and to emit the
brake signal to the ABS module.

When the system comes into operation, ABS module detects the operation of all parts of the system. Once the
system or parts have faults, the system will switch on the ABS warning light to remind drivers of repair in time.
Service Hints
• C004 Stop Lamp Switch
1 - 2: Closed with the brake pedal depressed.
Parts Location

C004 Instrument Panel Wire Harness C601 Diagnosis Wire Harness
C015 Instrument Panel Wire Harness L006 Chassis Wire Harness LH


A101 C106

A104 C107

C101 L101

C109 C701
Ground Points
Code Ground Points Location

C245 Left Side of the Washer Pump
ANTI-LOCK BRAKE SYSTEM - WITH BJ493ZQ3 ENGINE
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System Description
Anti-lock braking system (ABS) uses wheel speed sensor to detect wheel speed and transmits the wheel
speed signal to the control module. The control module controls wheel slipping rate by repeatedly increasing
or decreasing the wheel brake pressure according to the input wheel speed, keep the wheels rotating. The
system enables the vehicle in braking state to prevent the wheels locking and have the steering capability,
guaranteeing stability in the braking direction and preventing side-slipping and deviation.
• Signal Input
The current flows through fuse F9 and fuse F10 in body junction box, to pin 9 and pin 25 of ABS module. ABS
actuator and solenoid valve are then powered.
When ignition switch is ON/ST, the current flows through fuse F3 in body junction box, pin 4 of ABS module,
and to emit the ignition signal to the ABS module.
Speen Sensor Signal

The speed of the wheels is detected and input by front wheel speed sensor LH, front wheel speed sensor RH,
rear wheel speed sensor LH and rear wheel speed sensor RH.
Brake Signal
The current flows through fusible link FL6 in engine room junction box, to pin 2 of main relay, pin 3 of stop lamp
switch. When the brake pedal is depressed, the current flows from pin 2 of stop lamp switch, to pin18 of ABS
module, and to emit the brake signal to the ABS module.

When the system comes into operation, ABS module detects the operation of all parts of the system. Once the
system or parts have faults, the system will switch on the ABS warning light to remind drivers of repair in time.
Service Hints
2 - 3: Closed with the brake pedal depressed.
Parts Location

C015 Instrument Panel Wire Harness C601 Diagnosis Wire Harness


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A101 C106
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A102 C108

A104 C107

C101 L101

C109 C701
Ground Points

C245 Left Side of the Washer Pump

System Description
When a car collides with an obstacle, it will quickly open an airbag filled with air, so that the occupants can
throw themselves on the airbag when moving due to inertia, thereby easing the impact on occupants and 71
absorbing collision energy to reduce personal injuries.
When ignition switch is ON/ST, the current flows through fuse F17 in body junction box, to pin 5 of restraint 71
control module. System is then powered.
When vehicle is in a frontal collision exceeding a specified level, the current flows from pin 10 of restraint
control module, to pin 1 of clock spring, to pin 1 of driver airbag. Current then flows from pin 2 of driver airbag,
to pin 2 of clock spring, and back to pin 11 of restraint control module. Driver airbag is then activated.
When vehicle is in a frontal collision exceeding a specified level, the current flows from pin 27 of restraint
control module, to pin 16 of multi-function door lock controller (4-in-1), and to emit the crash signal to the multi-
function door lock controller (4-in-1). The current then pass through pin 6 of multi-function door lock controller
(4-in-1). The following are activated:
a. The current flows through pin 1 of front door lock actuator LH, to the door lock motor. Current then pass
through pin 3 of front door lock actuator LH, and back to pin 7 of multi-function door lock controller (4-in-1).
This enables front door LH to open.
b. The current flows through pin 4 of front door lock actuator RH, to the door lock motor. Current then pass
through pin 2 of front door lock actuator RH, and back to pin 7 of multi-function door lock controller (4-in-1).
This enables front door RH to open.
c. The current flows through pin 1 of sliding door lock actuator LH, to the door lock motor. Current then pass
through pin 3 of sliding door lock actuator LH, and back to pin 7 of multi-function door lock controller (4-in-1).
This enables sliding door LH to open.
d. The current flows through pin 1 of sliding door lock actuator RH, to the door lock motor. Current then pass
through pin 3 of sliding door lock actuator RH, and back to pin 7 of multi-function door lock controller (4-in-1).
This enables sliding door RH to open.
e. The current flows through pin 2 of rear hatch lock actuator, to the door lock motor. Current then pass
through pin 1 of rear hatch lock actuator, and back to pin 7 of multi-function door lock controller (4-in-1). This
enables rear hatch to open.

When the system comes into operation, restraint control module detects the operation of all parts of the
system. Once the system or parts have faults, the system will switch on the SRS warning light to remind
drivers of repair in time.
Parts Location

A301 Engine Room Wire Harness C601 Diagnosis Wire Harness
C027 Instrument Panel Wire Harness J004 Rear Hatch Wire Harness #2
C030 Instrument Panel Wire Harness K003 Chassis Wire Harness RH
C045 Instrument Panel Wire Harness M001 Front Door Wire Harness RH
C061 Instrument Panel Wire Harness N006 Front Door Wire Harness LH


A104 C107

C101 L101

C109 C701

C112 M101

C115 Q103

C120 N103
Roof Wire Harness & Instrument Panel Wire Harness

F101 C110
(Beside A-Pillar, on the Right Side of the Instrument Panel)
Roof Wire Harness & Rear Hatch Wire Harness #1

F103 I102

G103 K101

I103 J101
(Sliding Door LH)

Q101 G102
Ground Points

C213 Left Side of the Instrument Panel
INSTRUMENT CLUSTER
INSTRUMENT CLUSTER - WITH 4G63/4G64 ENGINE
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System Description
The current flows through fuse F26 in engine room junction box, to pin 11 of instrument cluster. System is then
powered. 71
When ignition switch is ON/ST, the current pass through fuse F1 in body junction box, to pin 13 of instrument
cluster, and to emit the ignition signal to the instrument cluster. 71
Engine Coolant Temperature Warning Light/Engine Coolant Temaperature Indicator Light
The current flows from pin 23 of instrument cluster and through coolant temperature indicator to ground. This
checks the engine coolant temperature.
When ignition switch is ON/ST, the current pass through fuse F17 in body junction box, to pin 1 of engine
coolant fluid level sensor. Current then flows from pin 2 of engine coolant fluid level sensor to pin 2 of
instrument cluster. This checks the engine coolant fluid level.
Door Ajar Warning Light

If any one of the doors is not fully closed, door ajar switch will be closed. The current flows from pin 1 of instru-
ment cluster to door ajar switch, and then to ground. This enables door ajar warning light to operate.
Engine Oil Pressure Warning Light

The current flows from pin 9 of instrument cluster to pin 1 of engine oil pressure switch, and then to ground.
This checks the engine oil pressure.
Fuel Level Warning Light

The current flows from pin 21 of instrument cluster to pin 1 of fuel level sensor. Power is ground at pin 2 of fuel
level sensor. This checks the fuel pressure.
Malfunction Indicator Light

If a malfunction occurs in engine control system, the current flows from pin 20 of instrument cluster to pin 31 of
engine control module. This enables malfunction indicator light to operate.
SVS Indicator Light

The current flows from pin 31 of instrument cluster to pin 29 of engine control module. Engine control module
enables SVS indicator light to operate.
Charging Warning Light

The current flows from pin 16 of instrument cluster to pin 1 of generator. This identified if the generator oper-
ated or not.
ABS Warning Light

The current flows from pin 15 of ABS module to pin 14 of instrument cluster. Power is ground at pin 3 of instru-
ment cluster. This enables ABS warning light to operate.
EBD Warning Light

ment cluster. This enables EBD warning light to operate.
Seat Belt Warning Light

The current flows from pin 19 of instrument cluster to pin 1 of seat belt buckle switch. Power is ground at pin 2
of seat belt buckle switch. This checks the seat belt is buckled or not.
SRS Warning Light

The current flows from pin 17 of instrument cluster to pin 7 of restraint control module. Restraint control mod-
ule enables SRS warning light to operate.
Brake Warning Light

The current flows from pin 26 of instrument cluster to pin 1 of parking brake switch, and then to ground. This
checks if the parking brake is applied or not.
The current flows from pin 26 of instrument cluster to pin 1 of brake fluid level sensor. Power is ground at pin 2
of brake fluid level sensor. This checks the brake fluid level.
Parts Location

A301 Engine Room Wire Harness G001 Rear Body Wire Harness RH
C012 Instrument Panel Wire Harness G003 Rear Body Wire Harness RH
C027 Instrument Panel Wire Harness H001 Rear Body Wire Harness LH
E019 Engine Control Wire Harness

A101 C106

A104 C107

C101 L101

C115 Q103

C116 Q104

E102 C102
(Under A-Pillar, on the Left Side of the Instrument Panel)

E103 C103

F101 C110

F103 I102

G103 K101

G104 H101

I101 F104
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I103 J101
(Sliding Door LH) 71
Q101 G102

Q102 G101
Ground Points

C212 Left Side of the Instrument Panel C246 Right Side of the Instrument Panel
INSTRUMENT CLUSTER - WITH BJ493ZQ3 ENGINE

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System Description
The current flows through fuse F26 in engine room junction box, to pin 11 of instrument cluster. System is then
powered.
cluster, and to emit the ignition signal to the instrument cluster.
Engine Cooalnt Temperature Warning Light/Engine Coolant Temperature Indicator Light

The current flows from pin 23 of instrument cluster and through coolant temperature indicator to ground. This
checks the engine coolant temperature.
The current flows through fuse FL6 in engine room junction box, to pin 1 of engine coolant fluid level sensor.
Current then flows from pin2 of engine coolant fluid level sensor to pin 2 of instrument cluster. This checks the
engine coolant fluid level.
Door Ajar Warning Light

If any one of the doors is not fully closed, door ajar switch will be closed. The current flows from pin 1 of instrument
cluster to door ajar switch, and then to ground. This enables door ajar warning light to operate.
Engine Oil Pressure Warning Light

The current flows from pin 9 of instrument cluster to pin 1 of engine oil pressure switch, and then to ground.
This checks the engine oil pressure.
Fuel Level Warning Light

The current flows from pin 21 of instrument cluster to pin 1 of fuel level sensor. Power is ground at pin 2 of fuel
level sensor. This checks the fuel pressure.
Charging Warning Light

The current flows from pin 16 of instrument cluster to pin 1 of generator. This identified if the generator oper-
ated or not.
ABS Warning Light

ment cluster. This enables ABS warning light to operate.
EBD Warning Light

The current flows from pin 14 of ABS module to pin 28 of instrument cluster. Power is ground at pin 3 of
instrument cluster. This enables EBD warning light to operate.
Seat Belt Warning Light

The current flows from pin 19 of instrument cluster to pin 1 of seat belt buckle switch. Power is ground at pin 2
of seat belt buckle switch. This checks the seat belt is buckled or not.
Brake Warning Light

The current flows from pin 26 of instrument cluster to pin 1 of parking brake switch, and then to ground. This
checks if the parking brake is applied or not.
The current flows from pin 26 of instrument cluster to pin 1 of brake fluid level sensor. Power is ground at pin 2
of brake fluid level sensor. This checks the brake fluid level.
Sediment Water Indicator Light

The current flows from pin 2 of oil water separator to pin 30 of instrument cluster, though sediment water indi-
cator light to ground at pin 32 of instrument cluster.This enables sediment water indicator light to operate.
Malfunction Indicator Light

The current flows through fusible link FL6 in engine room junction box, to main relay R2. Coil of main relay R2
controlled by engine control system. Coil then creates a magnetic field, and switch is activated. The current
flows from main relay R2 to fuse F20 in body junction box, to pin 4 of instrument cluster. The current then flows
from pin 20 of instrument cluster to pin K91 of engine control module. This enables malfunction indicator light
to operate.
Preheat Indicator Light

The current flows through fusible link FL6 in engine room junction box, to main relay R2. Coil of main relay R2
is controlled by engine control system. Coil then creates a magnetic field, and switch is activated. The current
flows from main relay R2 to fuse F20 in body junction box, to pin 4 of instrument cluster. The current then flows 71
from pin 8 of instrument cluster to pin K92 of engine control module. This enables preheat indicator light to
operate.
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Parts Location

A003 Engine Room Wire Harness E304 Engine Room Sub-harness
A016 Engine Room Wire Harness J005 Rear Hatch Wire Harness #2
A301 Engine Room Wire Harness K002 Chassis Wire Harness RH
C301 Instrument Panel Wire Harness Q004 Front Body Wire Harness

A101 C106

A102 C108

A104 C107

C101 L101

C122 Q107

E106 C123
E400 A105 Engine Room Sub-harness & Engine Room Wire Harness

F101 C110

F103 I102

G103 K101

I101 F104

I103 J101
(Sliding Door LH)

Q101 G102

Q105 G105

Q106 C121
Ground Points

C243 Right Side of the Instrument Panel

STARTING SYSTEM
STARTING AND IGNITION - WITH 4G63/4G64 ENGINE
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System Description
Starting System
When ignition switch is turned to ST, the current flows through fuse F24 in engine room junction box, to pin
AM2 of ignition switch. The current flows from pin ST2 of ignition switch to fuse F16 in body junction box, to pin
3 of starter relay R5, and through coil to ground at pin 2 of starter relay R5. Coil then creates a magnetic field,
and switch is activated. The current flows through fusible link FL1 in engine room junction box, through starter
relay R5, to solenoid switch of starter. Solenoid switch creates a magnetic field, and starter is activated.
The current flows through the “B” terminal of starter, to starter motor, and to crank the engine.
Ignition System
When ignition switch is ON/ST, the current flows through fuse F24 in engine room junction box, to pin AM2 of
ignition switch. The current flows from pin IG2 of ignition switch to fuse F17 in body junction box, to pin 1 of
engine control module, and to emit the ignition signal to engine control module.
The current flows through pin IG2 of ignition switch to pin 2 of ignition coil, and through primary coil, to pin 32
and 52 of engine control module. This induces the proper high voltage in the secondary coil.
The engine control module receives information such as crankshaft position sensor signal and manifold
absolute pressure sensor signal, to identify NO.1 cylinder BTDC (Before Top Dead Center), firing order and
fuel supply quantity.
Firing order: 1 – 3 – 4 – 2
Service Hints
AM2 – IG2: Closed with the ignition switch at ON/ST position.
AM2 – ST2: Closed with the ignition switch at ST position.
Parts Location

A411 Battery Wire Harness E013 Engine Control Wire Harness

A102 C108

A104 C107

E102 C102

E103 C103
Ground Points

A202 Left Side of the Engine Room E201 on the Clutch House, near Starter
STARTING - WITH BJ493ZQ3 ENGINE
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System Description
When ignition switch is turned to ST, the current flows through fuse F24 in engine room junction box, to pin
AM2 of ignition switch. The current flows from pin ST2 of ignition switch to fuse F16 in body junction box, to pin
3 of starter relay R5, and through coil to ground at pin 2 of starter relay R5. Coil then creates a magnetic field,
and switch is activated.
The current flows through fusible link FL6 in engine room junction box, through starter relay R5, to solenoid
switch of starter. Solenoid switch creates a magnetic field, and starter is activated.
The current flows through the “B” terminal of starter, to starter motor, and to crank the engine.
Service Hints
AM2 – ST2: Closed with the ignition switch at ST position.
• R5 Starter Relay
1 – 4: Points closed with the ignition switch at ST position.
Parts Location

A411 Battery Wire Harness C301 Instrument Panel Wire Harness
A412 Battery Wire Harness

A104 C107
E401 A501 Engine Room Sub-harness & Battery Wire Harness
Ground Points

A202 Left Side of the Engine Room
CHARGING SYSTEM
CHARGING SYSTEM - WITH 4G63/4G64
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System Description
cluster (charging warning light). The current then flows through pin 1 (“IG” terminal) of generator connector
E019 (voltage regulator), to field winding of generator. Field winding creates a magnetic field.
Rotation of the excited field coil generates AC voltage in the stator. The alternation current is rectified through
diodes to DC voltage, to pin B of generator connector E018, to fusible link FL0 in fusible link box. This charge
a battery, and supply electrical energy to other electrical devices.
The electrical energy pass through fuse F21 in engine room junction box, to pin 2 (“S” terminal) of generator
connector E019 (voltage regulator). This regulates differential voltage between output voltage of generator
and voltage regulator.
Service Hints
• E019 Generator
2 – Ground: 14 volts with the engine running at 6000 RPM.
1 – Ground: 6 volts with the ignition switch at ON position and engine not running.
Parts Location


A104 C107

E102 C102

E103 C103
CHARGING SYSTEM - WITH BJ493ZQ3 ENGINE
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System Description
When ignition switch is ON/ST, the current pass through ignition switch, pin 1 (“IG” terminal) of generator
connector E302.
At the same time, the current flows from fuse F1 in body junction box, to pin 13 of instrument cluster (charging
warning light), from pin 16 of instrument cluster, and then to pin 1 (“L” terminal) of generator connector E304.
The current flows through voltage regulator, field winding of generator. Field winding creates a magnetic field.
Rotation of the excited field coil generates AC voltage in the stator. The alternation current is rectified through
diodes to DC voltage, to pin B of generator connector E303, to fusible link FL0 in fusible link box. This charge
a battery, and supply electrical energy to other electrical devices.
The electrical energy pass through pin 2 (“S” terminal) of generator connector E304 (voltage regulator). This
regulates differential voltage between output voltage of generator and voltage regulator.
Service Hints
• E302 Generator
• E304 Generator
Parts Location

C045 Instrument Panel Wire Harness E303 Engine Room Sub-harness
E302 Engine Room Sub-harness

A101 C106

A104 C107
LIGHTING SYSTEM
HEADLAMP
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71
System Description
Headlamp (Low Beam)
The current flows through fusible link FL3 in engine room junction box, to pin 1 and pin 5 of headlamp relay
R3, through coil of headlamp relay R3, and then to pin 13 of combination switch. When the combination switch
is set headlamp (Low Beam) position, power is ground at pin 16 of combination switch. The coil of headlamp
relay R3 creates a magnetic field, and switch is activated. The current flows through fuse F11 and fuse F12 in
body junction box, to pin 5 of front combination lamp LH and pin 5 of front combination lamp RH, and then to
pin 17 of combination switch. The power is ground at pin 16 of combination switch. This enables headlamp
(Low Beam) to operate.
Headlamp (High Beam)

is set headlamp (High Beam) position, power is ground at pin 16 of combination switch. The coil of headlamp
relay R3 creates a magnetic field, and switch is activated. The current flows through fuse F11 and fuse F12 in
body junction box, to pin 5 of front combination lamp LH and pin 5 of front combination lamp RH, and then to
pin 7 of combination switch. The power is ground at pin 16 of combination switch. This enables headlamp
(High Beam) to operate.
High Beam Indicator Light

When the combination switch is set headlamp (Low Beam) position, power is ground at pin 17 of combination
switch. So the both ends of high beam indicator light at the same potential, the indicate light is inoperable.
When the combination switch is set headlamp (High Beam) position, pin 17 of combination switch is open, and
pin 17 of combination switch is in high potential. So the current flows through pin 25 of combination switch,
through high beam indicator light, and ground at pin 3 of combination switch. This enables high beam indicator
light to operate.
Flash to Pass
is set Flash to Pass position, power is ground at pin 16 of combination switch. The coil of headlamp relay R3
creates a magnetic field, and switch is activated. The current flows through fuse F11 and fuse F12 in body
junction box, to pin 5 of front combination lamp LH and pin 5 of front combination lamp RH, and then to pin 7 of
combination switch. The power is ground at pin 16 of combination switch. This enables Flash to Pass to
operate.
Service Hints
• C040 Combination Switch
13 – 16: Closed with the combination switch at Headlamp position (High Beam and Low Beam).
17 – 16: Closed with the combination switch at Headlamp position (Low Beam).
7 – 16: Closed with the combination switch at Headlamp position (High Beam).
8 – 16: Closed with the combination switch at Flash to Pass position.
Parts Location


71
A101 C106
71
Ground Points

C214 Right Side of the Instrument Panel C246 Right Side of the Instrument Panel
PARKING, LICENSE AND TAIL LAMPS

System Description
Parking Lamp
The current flows through fusible link FL1 (or FL6 ) in engine room junction box, to pin 2 and pin 5 of parking 71
lamp relay R4, through coil of parking lamp relay R4, and then to pin 14 of combination switch. When the
combination switch is set parking lamp or headlamp (Low Beam/High Beam) position, power is ground at pin
16 of combination switch. The coil of parking lamp relay R4 creates a magnetic field, and switch is activated. 71
The current flows through fuse F18 in body junction box, to pin 1 of front combination lamp LH and pin 1 of
front combination lamp RH. The power is ground at pin 4 of front combination lamp LH and pin 4 of front
combination lamp RH. This enables parking lamp to operate.
Tail Lamp
The current flows through fusible link FL1 (or FL6 ) in engine room junction box, to pin 2 and pin 5 of parking
16 of combination switch. The coil of parking lamp relay R4 creates a magnetic field, and switch is activated.
The current flows through fuse F18 in body junction box, to pin 1 of rear combination lamp LH and pin 1 of rear
combination lamp RH. The power is ground at pin 4 of rear combination lamp LH and pin 4 of rear combination
lamp RH. This enables tail lamp to operate.
License Lamp
The current flows through fusible link FL1 (or FL6 ) in engine room junction box, to pin 2 and pin 5 of parking
16 of combination switch. The coil of parking lamp relay R4 creates a magnetic field, and switch is activated.
The current flows through fuse F18 in body junction box, to pin 1 of license lamp. The power is ground at pin 2
of license lamp. This enables license lamp to operate.
Service Hints
14 – 16: Closed with the combination switch at parking lamp or headlamp (Low Beam/High Beam) position.
Parts Location

A301 Engine Room Wire Harness H005 Rear Body Wire Harness LH

A101 C106

A104 C107

C116 Q104

Q106 C121

F101 C110

F103 I102

G104 H101

I101 F104

I103 J101
(Sliding Door LH)

Q101 G102
Ground Points

A201 Left Side of the Engine Room F205 Above Rear Window RH
A204 Right Side of the Engine Room G201 Above Rear Wheelhouse RH

STOP LAMP - WITH 4G63/4G64 ENGINE
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System Description
The current flows through fuse F27 in engine room junction box, to pin 2 of stop lamp switch. The stop lamp
switch closed with the brake pedal depressed. The current then flows from pin 1 of stop lamp switch to pin 2 of
rear combination lamp LH, pin 2 of rear combination lamp RH and pin 2 of high-mounted stop lamp. The
power is ground at pin 4 of rear combination lamp LH, pin 4 of rear combination lamp RH and pin 1 of high-
mounted stop lamp. This enables stop lamp and high-mounted stop lamp to operate.
Service Hints
1 – 2: Closed with the brake pedal depressed.
Parts Location

C004 Instrument Panel Wire Harness I001 Rear Hatch Wire Harness #1
G005 Rear Body Wire Harness RH

A101 C106

C116 Q104

F101 C110

F103 I102

G104 H101

I101 F104

Q101 G102
Ground Points

F205 Above Rear Window RH H201 Above Rear Wheelhouse LH
G201 Above Rear Wheelhouse RH

STOP LAMP - WITH BJ493ZQ3 ENGINE
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71
System Description
The current flows through fusible link FL6 in engine room junction box, to pin 2 and pin 3 of main relay R2,
through the coil of main relay, to pin K72 of engine control module. The coil of main relay R2 is controlled by
engine control module and then creates a magnetic field, and switch is activated. The current flows from fuse
F20 in body junction box to pin 3 of stop lamp switch. The stop lamp switch closed with the brake pedal
depressed. The current then flows from pin 2 of stop lamp switch to pin 2 of rear combination lamp LH, pin 2 of
rear combination lamp RH and pin 2 of high-mounted stop lamp. The power is ground at pin 4 of rear
combination lamp LH, pin 4 of rear combination lamp RH and pin 1 of high-mounted stop lamp. This enables
stop lamp and high-mounted stop lamp to operate.
Service Hints
1 – 4: Open with the brake pedal depressed.
2 – 3: Closed with the brake pedal depressed.
Parts Location

C051 Instrument Panel Wire Harness I001 Rear Hatch Wire Harness #1

A102 C108

A104 C107

C122 Q107

F101 C110

F103 I102

G104 H101

I101 F104

Q101 G102

Q106 C121
Ground Points

71
F205 Above Rear Window RH H201 Above Rear Wheelhouse LH
G201 Above Rear Wheelhouse RH 71

BACK-UP LAMP - WITH 4G63/4G64 ENGINE

System Description
When ignition switch is ON/ST, the current flows through fuse F1 in body junction box, to pin 2 of back-up lamp
switch. The current flows from pin 1 of back-up lamp switch, and then to the circuit as follows:
71
a.The current pass through pin 5 of rear combination lamp LH, and ground at pin 4 of rear combination lamp
LH. This enables rear back-up lamp LH to operate.
b.The current pass through pin 5 of rear combination lamp RH, and ground at pin 4 of rear combination lamp 71
RH. This enables rear back-up lamp RH to operate.
c.The current pass through pin 1 of reverse radar controller. Reverse radar controller is then powered.
Service Hints
• E011 Back-up Lamp Switch
1 – 2: Closed with the shift lever in “R” position.
Parts Location


C116 Q104

E102 C102

G104 H101

Q101 G102
Ground Points

G201 Above Rear Wheelhouse RH H201 Above Rear Wheelhouse LH
BACK-UP LAMP - WITH BJ493ZQ3 ENGINE

System Description
switch. The current flows from pin 1 of back-up lamp switch, and then to the circuit as follows:
71
a.The current pass through pin 5 of rear combination lamp LH, and ground at pin 4 of rear combination lamp
LH. This enables rear back-up lamp LH to operate.
b.The current pass through pin 5 of rear combination lamp RH, and ground at pin 4 of rear combination lamp 71
RH. This enables rear back-up lamp RH to operate.
Service Hints
• K004 Back-up Lamp Switch
Parts Location

G005 Rear Body Wire Harness RH K004 Chassis Wire Harness RH

C122 Q107

G103 K101

G104 H101

Q101 G102
Ground Points

G201 Above Rear Wheelhouse RH H201 Above Rear Wheelhouse LH
TURN SIGNAL AND HAZARD WARNING LAMPS

System Description
The current flows through fuse F23 in engine room junction box, to pin 1 of multi-function controller (3-in-1)
connector C003. Multi-function controller (3-in-1) is then powered. When ignition switch is ON/ST, the current
71
flows through fuse F5 in body junction box, to pin 10 of hazard switch. When hazard switch is in OFF position,
the current flows from pin 7 of hazard switch, to pin 9 of multi-function controller (3-in-1) connector C002, and
emit the operation signal to multi-function controller (3-in-1). 71
Turn Signal Lamp LH

When the combination switch is in Left Turn position, the current flows through pin 12 of multi-function
controller (3-in-1) connector C002, pin 2 of combination switch. The current then flows from pin 1 of
combination switch, to the circuit as follows:
a.The current pass through pin 1 of front combination lamp LH, and ground at pin 2 of front combination lamp
LH. This enables front turn signal lamp LH to operate.
b.The current pass through pin 3 of rear combination lamp LH, and ground at pin 4 of rear combination lamp
LH. This enables rear turn signal lamp LH to operate.
c.The current pass through pin 7 of outside mirror LH, and ground at pin 6 of outside mirror LH. This enables
turn signal lamp LH of outside mirror to operate.
d.The current pass through pin 22 of instrument cluster, and ground at pin 3 of instrument cluster. This enables
left turn signal/hazard indicator light to operate.
Turn Signal Lamp RH

When the combination switch is in Right Turn position, the current flows through pin 12 of multi-function
controller (3-in-1) connector C002, pin 2 of combination switch. The current then flows from pin 3 of
combination switch, to the circuit as follows:
a.The current pass through pin 1 of front combination lamp RH, and ground at pin 2 of front combination lamp
RH. This enables front turn signal lamp RH to operate.
b.The current pass through pin 3 of rear combination lamp RH, and ground at pin 4 of rear combination lamp
RH. This enables rear turn signal lamp RH to operate.
c.The current pass through pin 7 of outside mirror RH, and ground at pin 6 of outside mirror RH. This enables
turn signal lamp RH of outside mirror to operate.
right turn signal/hazard indicator light to operate.
Hazard Lamp
The current flows through fuse F23 in engine room junction box, to pin 1 of multi-function controller (3-in-1)
connector C003. Multi-function controller (3-in-1) is then powered. When the ignition switch is in OFF, there is
no ignition signal emit to the multi-function controller (3-in-1).
When the hazard switch is pressed, the current flows through fuse F25 in engine room junction box, pin 8 of
hazard switch. The current flows from pin 7 of hazard switch to pin 9 of multi-function controller (3-in-1)
connector C002, and emit the operation signal to multi-function controller (3-in-1). The current then flows from
pin 12 of multi-function controller (3-in-1) connector C002, to pin 9 of hazard switch, outputs from pin 5 and pin
6 of hazard switch:
The current outputs from pin 5 of hazard switch as follows:
a.The current pass through pin 1 of front combination lamp LH, and ground at pin 2 of front combination lamp
LH. This enables front turn signal lamp LH to operate.
b.The current pass through pin 3 of rear combination lamp LH, and ground at pin 4 of rear combination lamp
LH. This enables rear turn signal lamp LH to operate.
c.The current pass through pin 7 of outside mirror LH, and ground at pin 6 of outside mirror LH. This enables
turn signal lamp LH of outside mirror to operate.
left turn signal/hazard indicator light to operate.
The current outputs from pin 6 of hazard switch as follows:
a.The current pass through pin 1 of front combination lamp RH, and ground at pin 2 of front combination lamp
RH. This enables front turn signal lamp RH to operate.
b.The current pass through pin 3 of rear combination lamp RH, and ground at pin 4 of rear combination lamp
RH. This enables rear turn signal lamp RH to operate.
c.The current pass through pin 7 of outside mirror RH, and ground at pin 6 of outside mirror RH. This enables
turn signal lamp RH of outside mirror to operate.
right turn signal/hazard indicator light to operate.
Service Hints
• C034 Hazard Switch
7 – 10: Closed with the hazard switch released.
7 – 8: Closed with the hazard switch pressed.
9 – 5 – 6: Closed with the hazard switch pressed.
1 – 2: Closed with the combination switch at Left Turn position.
2 – 3: Closed with the combination switch at Right Turn position.
Parts Location


A101 C106

C104 N102

C112 M101

C114 M102

C116 Q104

C120 N103

G104 H101

Q101 G102

Q106 C121
Ground Points

71
A204 Right Side of the Engine Room C246 Right Side of the Instrument Panel 71
C212 Left Side of the Instrument Panel H201 Above Rear Wheelhouse LH

FOG LAMP
System Description
Front Fog Lamp
Operation requirement: Always turn on parking lamp. 71
The current flows through fusible link FL1 (or FL6) in engine room junction box, to pin 2 and pin 5 of parking
lamp relay R4, and through coil of parking lamp relay to pin 14 of combination switch. When combination
switch is set parking lamp position, the power is ground at pin 16 of combination switch. The coil of parking 71
lamp relay R4 creates a magnetic field, and switch is activated. The current flows from parking lamp relay R4
to coil of front fog lamp relay R7, and to pin 11 of combination switch. When combination switch is set front fog
lamp position, the power is ground at pin 10 of combination switch. The coil of front fog lamp relay R7creates
a magnetic field, and switch is activated. The current flows through fuse F22 in engine room junction box, to
front fog lamp relay R7, and to front fog lamp LH, front fog lamp RH and front fog lamp indicator light. The
power is ground at pin 2 of front fog lamp LH, pin 2 of front fog lamp RH and pin 3 of instrument cluster. This
enables front fog lamp LH, front fog lamp RH and front fog lamp indicator light to operate.
Rear Fog Lamp

Operation requirement: Always turn on parking lamp, at the same time, turn on headlamp or front fog lamp
either.
The current flows through fuse F23 in engine room junction box, to pin 1 of multi-function controller (3-in-1).
When combination switch is set parking lamp position, the current flows through parking lamp relay R4, to fuse
F19 in body junction box, to pin 8 of multi-function controller (3-in-1), and emit the parking lamp signal to multi-
function controller.
When combination switch is set front fog lamp position, the current flows through pin 7 of multi-function
controller (3-in-1), pin 11 of combination switch. The power is ground at pin 10 of combination switch.
When combination switch is set headlamp position, the current flows through pin 6 of multi-function controller
(3-in-1), pin 13 of combination switch. The power is ground at pin 16 of combination switch.
When rear fog lamp switch is turned to OFF, the current flows through pin 3 of multi-function controller (3-in-1),
pin 6 of rear fog lamp switch. The power is ground at pin 3 of rear fog lamp switch. When multi-function
controller (3-in-1) received rear fog lamp operation signal, the current flows from pin 2 of multi-function
controller (3-in-1), to rear fog lamp LH, rear fog lamp RH, the working light of rear fog lamp switch and rear fog
lamp indication light. The power is ground at pin 2 of rear fog lamp LH, pin 2 of rear fog lamp RH, pin 3 of rear
fog lamp switch and pin 3 of instrument cluster. This enables rear fog lamp LH, rear fog lamp RH, working light
of rear fog lamp switch and rear fog lamp indication light to operate.
Service Hints
14 – 16: Closed with the combination switch at Parking Lamp position, Headlamp position and Front Fog
Lamp position.
13 – 16: Closed with the combination switch at Headlamp position.
10 – 11: Closed with the combination switch at Front Fog Lamp position.
Parts Location

C001 Instrument Panel Wire Harness D002 Rear Fog Lamp Wire Harness

A101 C106

A104 C107

C116 Q104

G104 H101
H102 D101

Q101 G102

Q106 C121
Ground Points


INTERIOR LAMPS
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71
System Description
Frong Indoor Lamp
The current flows through fusible link FL3 in engine room junction box, to fuse F13 in body junction box, to pin
1 of front indoor lamp. Press front indoor lamp switch LH (front indoor lamp switch RH), and the power is
ground by the switch. This enables front indoor lamp to operate;
If any front door is not closed, the front door ajar switch will turn to ON. The current flows from pin 2 of front
indoor lamp, and the power is ground by ajar the switch. This enables front indoor lamp to operate.
Rear Indoor Lamp

3 of rear indoor lamp. Press rear indoor lamp switch, and the power is ground at pin 1 of rear indoor lamp
switch. This enables rear indoor lamp to operate;
If any sliding door is not closed, the door ajar switch will turn to ON. The current flows from pin 2 of rear indoor
lamp, and the power is ground by the ajar switch. This enables rear indoor lamp to operate.
Sliding Door Step Lamp LH/RH

1 of sliding door step lamp LH/RH. If any sliding door is not closed, the sliding door ajar switch will turn to ON.
The current flows from pin 2 of sliding door step lamp LH/RH, and the power is ground by ajar switch. This
enables sliding door step lamp LH/RH to operate.
Cargo Lamp
1 of cargo lamp. If the rear hatch is not closed, the rear hatch ajar switch will turn to ON, the current flows from
pin 2 of cargo lamp, and the power is ground by ajar switch. This enables cargo lamp to operate.
Rear Evaporator Control Panel Illumination LH/RH

1 of rear evaporator control panel illumination LH/RH, the switch will turn to OFF, and the power is ground at
pin 2 of rear evaporator control panel illumination LH/RH. This enables rear evaporator control panel
illumination LH/RH to operate.
Parts Location

F001 Roof Wire Harness J005 Rear Hatch Wire Harness #2
F004 Roof Wire Harness K002 Chassis Wire Harness RH
F307 Rear Evaporator Wire Harness L001 Chassis Wire Harness LH
F308 Rear Evaporator Wire Harness L003 Chassis Wire Harness LH


71
A104 C107
71
C101 L101

C115 Q103

C116 Q104

C122 Q107

F101 C110

F103 I102

F105 F401

G103 K101

I101 F104

I103 J101
(Sliding Door LH)

Q101 G102

Q102 G101

Q106 C121
Ground Points

F205 Above Rear Window RH F236 Above Rear Window RH
ILLUMINATION
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71
System Description
The current flows through fusible link FL1 (or FL6) in engine room junction box, to pin 2 and pin 5 of parking
lamp relay R4, through coli of parking lamp relay, to pin 14 of combination switch. When combination switch is
set parking lamp position and headlamp position, the power is ground at pin 16 of combination switch. The coil
of parking lamp relay R4 creates a magnetic field, and switch is activated; the current flows from parking lamp
relay R4, to fuse F19 in body junction box, illumination is then powered.
Instrument Cluster Illumination

When ignition switch is ON/ST, the current flows through fuse F1 in body junction box, pin 13 of instrument
cluster. When combination switch is set parking lamp position and headlamp position, the current flows from
fuse F19 in body junction box, to pin 12 of instrument cluster, and emit illumination signal to instrument cluster.
This enables instrument cluster illumination to operate.
Electroinic Clock Illumination

When combination switch is set parking lamp position and headlamp position, the current flows from fuse F19
in body junction box, pin 3 of electronic clock. The power is ground at pin 1 of electronic clock. This enables
electronic clock illumination to operate.
Hazard Switch Illumination

in body junction box, pin 2 of hazard switch. The power is ground at pin 3 of hazard switch. This enables
hazard switch illumination to operate.
12V Power Point Socket Illumination

in body junction box, pin 3 of 12V power point socket. The power is ground at pin 2 of 12V power point socket.
This enables 12V power point socket illumination to operate.
Cigarette Light Illumination

in body junction box, pin 3 of cigarette lighter. The power is ground at pin 2 of cigarette lighter. This enables
cigarette lighter illumination to operate.
Front A/C Controller Illumination

in body junction box, pin 13 of front A/C controller. The power is ground at pin 14 of front A/C controller. This
enables front A/C controller illumination to operate.
Audio Illumination
in body junction box, pin 6 of audio. The power is ground at pin 8 of audio. This enables audio illumination to
operate.
Rear Fog Lamp Switch Illumination

in body junction box, pin 5 of rear fog lamp switch. The power is ground at pin 1 of rear fog lamp switch. This
enables rear fog lamp switch illumination to operate.
Outside Mirror Defrost Switch Illumination

in body junction box, pin 5 of outside mirror defrost switch. The power is ground at pin 1 of outside mirror
defrost switch. This enables outside mirror defrost switch illumination to operate.
Combined Display Illumination

in body junction box, pin 11 of combined display. The power is ground at pin 9 of combined display. This
enables combined display illumination to operate.
Rear Window Defrost Switch Illumination

in body junction box, pin 5 of rear window defrost switch. The power is ground at pin 1 of rear window defrost
switch. This enables rear window defrost switch illumination to operate. 71
Rear Heater Switch (Front Control) Illumination
71
in body junction box, pin 5 of rear heater switch (front control). The power is ground at pin 1 of rear heater
switch (front control). This enables rear heater switch (front control) illumination to operate.
Rear Heater Swtich (Rear Control) Illumination

in body junction box, pin 5 of rear heater switch (rear control). The power is ground at pin 1 of rear
heaterswitch (rear control). This enables rear heater switch (rear control) illumination to operate.
Rear A/C Switch (Front Control) Illumination

in body junction box, pin 5 of rear A/C switch (front control). The power is ground at pin 1 of rear A/C switch
(front control). This enables rear A/C switch (front control) illumination to operate.
Rear Heater Control Panel Illumination

in body junction box, pin 2 of rear heater control panel. The power is ground at pin 1 of rear heater control
panel. This enables rear heater control panel illumination to operate.
Service Hints
14 – 16: Closed with the combination switch at Parking Lamp position and Headlamp position.
Parts Location

C001 Instrument Panel Wire Harness C034 Instrument Panel Wire Harness
C021 Instrument Panel Wire Harness C401 Combined Display Wire Harness

A101 C106

A104 C107

C115 Q103

C122 Q107

C118 C501
Ground Points


POWER DOOR LOCK

POWER DOOR LOCK - WITH 4G63/4G64 ENGINE
71
71
System Description
The current flows through fusible link FL4 in engine room junction box, to pin 6 of main power window and
door lock/unlock switch, and pin 1 of multi-function door lock controller (4-in-1). System is then powered.
71
Ignition Signal
When ignition switch is ON/ST, the current flows through fuse F1 in body junction box, to pin 9 of multi-function 71
door lock controller (4-in-1), and emit the ignition signal to multi-function door lock controller (4-in-1).
Vehicle Speed Signal

The current flows from pin 3 of odometer sensor to pin 10 of multi-function door lock controller (4-in-1), and
emit the vehicle speed signal to multi-function door lock controller (4-in-1).
RCM Signal
The current flows from pin 27 of restraint control module to pin 16 of multi-function door lock controller (4-in-1),
and emit the door open automatically signal to the multi-function door lock controller (4-in-1) when SRS airbag
is activated.
Power Window and Door Lock/Unlock Signal

The data communication transmits from pin 4 and pin 5 of main power window and door lock/unlock switch,
to pin 11 and pin 12 of multi-function door lock controller (4-in-1), and then emit the door lock/unlock signal and
window up/down signal to multi-function door lock controller (4-in-1).
Door Lock/Unlock Signal

The current flows from pin 17 of multi-function door lock controller (4-in-1), to pin 4 of front door lock actuator
LH, through the switch, the power is ground at pin 2 of front door lock actuator LH. This emits the door open
signal to multi-function door lock controller (4-in-1).
LH, through the switch, the power is ground at pin 2 of front door lock actuator LH. This emits the door close
Door Ajar Signal

The current flows from pin 13 of multi-function door lock controller (4-in-1), to pin 1 of front door ajar switch LH,
pin1 of front door ajar switch RH, pin 1 of sliding door ajar switch LH, pin 1 of sliding door ajar switch RH and
pin 1 of rear hatch ajar switch; If any door is not closed, the door ajar switch will turn to ON. And door ajar
switch still open.
Door Lock Actuator Signal

a. The current flows from pin 6 of multi-function door lock controller (4-in-1), to pin 1 of front door lock actuator
LH, through door actuator, the current flows from pin 3 of front door lock actuator LH and back to pin 7 of multi-
function door lock controller (4-in-1). This enables front door LH open. On the contrary, the front door LH
closed.
b. The current flows from pin 6 of multi-function door lock controller (4-in-1), to pin 4 of front door lock actuator
RH, through door actuator, the current flows from pin 2 of front door lock actuator RH and back to pin 7 of
multi-function door lock controller (4-in-1). This enables front door RH open. On the contrary, the front door RH
closed.
c. The current flows from pin 6 of multi-function door lock controller (4-in-1), to pin 1 of sliding door lock
actuator LH, through door actuator, the current flows from pin 3 of sliding door lock actuator LH and back to pin
7 of multi-function door lock controller (4-in-1). This enables sliding door LH open. On the contrary, the sliding
door LH closed.
d. The current flows from pin 6 of multi-function door lock controller (4-in-1), to pin 1 of sliding door lock
actuator RH, through door actuator, the current flows from pin 3 of sliding door lock actuator RH and back to
pin 7 of multi-function door lock controller (4-in-1). This enables sliding door RH open. On the contrary, the
sliding door RH closed.
e. The current flows from pin 6 of multi-function door lock controller (4-in-1), to pin 2 of rear hatch lock actuator,
through door actuator, the current flows from pin 1 of rear hatch lock actuator and back to pin 7 of multi-
function door lock controller (4-in-1). This enables rear hatch open. On the contrary, the rear hatch closed.
Parts Location

E016 Engine Control Wire Harness M001 Front Door Wire Harness RH
G001 Rear Body Wire Harness RH N002 Front Door Wire Harness LH
H001 Rear Body Wire Harness LH

A104 C107

C101 L101

C104 N102

C105 N104

C112 M101

C115 Q103

C116 Q104

C120 N103

E102 C102

F101 C110

F103 I102

G103 K101

G104 H101
71
I101 F104
(D-Pillar RH, near Roof) 71
I103 J101
(Sliding Door LH)

Q101 G102

Q102 G101
Ground Points

C211 Left Side of the Instrument Panel J220 Under Rear Wiper Motor
POWER DOOR LOCK - WITH BJ493ZQ3 ENGINE

System Description
The current flows through fusible link FL4 in engine room junction box, to pin 6 of main power window and
door lock/unlock switch, and pin 1 of multi-function door lock controller (4-in-1). System is then powered.
71
Ignition Signal
When ignition switch is ON/ST, the current flows through fuse F1 in body junction box, to pin 9 of multi-function 71
Vehicle Speed Signal

The current flows from pin 3 of odometer sensor to pin 10 of multi-function door lock controller (4-in-1), and
emit the vehicle speed signal to multi-function door lock controller (4-in-1).
Power Window and Door Lock/Unlock Signal

The data communication transmits from pin 4 and pin 5 of main power window and door lock/unlock switch, to
pin 11 and pin 12 of multi-function door lock controller (4-in-1), and then emit the door lock/unlock signal and
window up/down signal to multi-function door lock controller (4-in-1).
Door Lock/Unlock Signal

LH, through the switch, the power is ground at pin 2 of front door lock actuator LH. This emits the door open
LH, through the switch, the power is ground at pin 2 of front door lock actuator LH. This emits the door close
Door Lock Actuator Signal

closed.
closed.
c. The current flows from pin 6 of multi-function door lock controller (4-in-1), to pin 1 of sliding door lock actua-
tor LH, through door actuator, the current flows from pin 3 of sliding door lock actuator LH and back to pin 7 of
multi-function door lock controller (4-in-1). This enables sliding door LH open. On the contrary, the sliding door
LH closed.
Parts Location

A301 Engine Room Wire Harness K005 Chassis Wire Harness RH
J004 Rear Hatch Wire Harness #2 N002 Front Door Wire Harness LH
K003 Chassis Wire Harness RH N006 Front Door Wire Harness LH


A104 C107

C101 L101

C104 N102

C105 N104

C112 M101

C120 N103

C122 Q107

F101 C110

F103 I102

G103 K101

I103 J101
(Sliding Door LH)

Q101 G102
Ground Points

C210 Left Side of the Instrument Panel C211 Left Side of the Instrument Panel
REMOTE KEYLESS ENTRY SYSTEM - WITH 4G63/4G64 ENGINE
71
71
System Description
The current flows through fusible link FL4 in engine room junction box, to pin 1 of multi-function door lock
controller (4-in-1). Multi-function door lock controller (4-in-1) is then powered.
71
Door Ajar Signal
The current flows from pin 13 of multi-function door lock controller (4-in-1), to pin 1 of front door ajar switch LH, 71
pin1 of front door ajar switch RH, pin 1 of sliding door ajar switch LH, pin 1 of sliding door ajar switch RH and
pin 1 of rear hatch ajar switch; If any door is not closed, the door ajar switch will turn to ON. And the door ajar
switch still open.
Door Lock Acturator Signal

closed.
closed.
c. The current flows from pin 6 of multi-function door lock controller (4-in-1), to pin 1 of sliding door lock
actuator LH, through door actuator, the current flows from pin 3 of sliding door lock actuator LH and back to pin
7 of multi-function door lock controller (4-in-1). This enables sliding door LH open. On the contrary, the sliding
door LH closed.
Turn Signal Lamp LH

The current flows from pin 15 of multi-function door lock controller (4-in-1), to the following circuits:
a. The current flows through pin 1 of front combination lamp LH. And the power is ground at pin 2 of front
combination lamp LH. This enables front turn signal lamp LH to operate.
b. The current flows through pin 3 of rear combination lamp LH. And the power is ground at pin 4 of rear
combination lamp LH. This enables rear turn signal lamp LH to operate.
c. The current flows through pin 7 of outside mirror LH. And the power is ground at pin 6 of outside mirror LH.
This enables turn signal lamp LH of outside mirror to operate.
d. The current flows through pin 22 of instrument cluster. And the power is ground at pin 3 of instrument
cluster. This enables left turn signal/hazard indicator light to operate.
Turn Signal Lamp RH

The current flows from pin 14 of multi-function door lock controller (4-in-1), to the following circuits:
a. The current flows through pin 1 of front combination lamp RH. And the power is ground at pin 2 of front
combination lamp RH. This enables front turn signal lamp RH to operate.
b. The current flows through pin 3 of rear combination lamp RH. And the power is ground at pin 4 of rear
combination lamp RH. This enables rear turn signal lamp RH to operate.
c. The current flows through pin 7 of outside mirror RH. And the power is ground at pin 6 of outside mirror RH.
This enables turn signal lamp RH of outside mirror to operate.
d. The current flows through pin 24 of instrument cluster. And the power is ground at pin 3 of instrument
cluster. This enables right turn signal/hazard indicator light to operate.
Parts Location

G001 Rear Body Wire Harness RH M001 Front Door Wire Harness RH
G003 Rear Body Wire Harness RH M005 Front Door Wire Harness RH
H001 Rear Body Wire Harness LH N006 Front Door Wire Harness LH

A101 C106

A104 C107

C101 L101

C104 N102

C112 M101

C114 M102

C115 Q103

C116 Q104

C120 N103

F101 C110

F103 I102

G103 K101

G104 H101
71
I101 F104
(D-Pillar RH, near Roof) 71
I103 J101
(Sliding Door LH)

Q101 G102

Q102 G101
Ground Points

POWER WINDOW CONTROL

System Description
The current flows through fusible link FL4 in engine room junction box, to pin 1 of multi-function door lock
controller (4-in-1) and pin 6 of main power window and door lock/unlock switch. System is then powered.
71
When ignition switch is ON/ST, the current flows through fuse F1 in body junction box, to pin 9 of multi-function
71
Front Power Window Motor LH Control
When pressing the front power window LH button of main power window and door lock/unlock switch, the
control signal flows from pin 4 and pin 5 of main power window and door lock/unlock switch, to pin 11 and pin
12 of multi-function door lock controller (4-in-1); the current flows from pin 4 of multi-function door lock
controller (4-in-1), to pin 2 of front power window motor LH, through the motor, the current then flows from pin
1 of front power window motor LH, to pin 5 of multi-function door lock controller (4-in-1). This enables front
power window LH up. On the contrary, the front power window LH down.
Front Power Window Motor RH Control

When pressing the front power window RH button of main power window and door lock/unlock switch, the
control signal flows from pin 4 and pin 5 of main power window and door lock/unlock switch, to pin 11 and pin
12 of multi-function door lock controller (4-in-1); the current flows from pin 2 of multi-function door lock
controller (4-in-1), to pin 2 of front power window motor RH, through the motor, the current then flows from pin
1 of front power window motor RH, to pin 3 of multi-function door lock controller (4-in-1). This enables front
power window RH up. On the contrary, the front power window RH down.
The current flows from pin 1 of main power window and door lock/unlock switch, to pin 1 of front power window
switch RH. When the front power window RH is in Up position, the current flows from pin 3 of front power
window switch RH, to pin 2 of main power window and door lock/unlock switch; When the front power window
RH is in Down position, the current flows from pin 4 of front power window switch RH, to pin 3 of main power
window and door lock/unlock switch; the control signal flows from pin 4 and pin 5 of main power window and
door lock/unlock switch, to pin 11 and pin 12 of multi-function door lock controller (4-in-1); the current flows
from pin 2 of multi-function door lock controller (4-in-1), to pin 2 of front power window motor RH, through the
motor, the current then flows from pin 1 of front power window motor RH, to pin 3 of multi-function door lock
controller (4-in-1). This enables front power window RH up. On the contrary, the front power window RH down.
Service Hints
• M002 Front Power Window Switch RH
1 – 3: Closed with the front power window switch RH in Up position.
1 – 4: Closed with the front power window switch RH in Down position.
Parts Location

A301 Engine Room Wire Harness M004 Front Door Wire Harness RH
M002 Front Door Wire Harness RH

A104 C107

C104 N102

C112 M101

C114 M102

C120 N103
Ground Points

HEATER AND AIR CONDITIONING CONTROL SYSTEM

AUTOMATIC AIR CONDITIONER CONTROL - WITH 4G63/4G64 ENGINE
71
71
71
71
System Description
When ignition switch is ON/ST, the current flows through fuse F2 in body junction box, to pin 4 of A/C cut relay.
The current then flows from pin 3 of A/C cut relay, to pin 10 of front A/C controller, pin 86 of front heater relay
R11, pin 3 and pin 13 of A/C amplifier, pin 1 and pin 2 of A/C clutch Relay, pin 2 of rear evaporator solenoid
and pin 5 of rear evaporator motor relay. System is then powered.
When ignition switch is ST, the current flows through fuse F16 in body junction box, to pin 2 of A/C cut relay,
through coil of A/C cut relay, the power is ground at pin 1 of A/C cut relay; the coil of A/C cut relay creates a
magnetic field, and switch is open. A/C system is then out of power, and ensure starting system operates in
normal.
Front A/C Control

When the blower switch is in OFF position, the current flows through pin 2 of front A/C controller, pin 2 of
blower switch. The power is ground at pin 3 of blower switch. This emits the blower signal to front A/C
controller.
When the blower switch is in operation, press the A/C switch of front A/C controller, the current flows through
pin 1 of front A/C controller, to pin 11 of A/C amplifier. This emits the front A/C switch input signal to A/C
amplifier.
The current flows through pin 18 of front A/C controller, to pin 5 of fresh/recirculation door actuator, through
motor, the current then flows from pin 7 of fresh/recirculation door actuator to pin 19 of front A/C controller.
This enables fresh/recirculation door actuator to operate.
The current flows through pin 15 of front A/C controller to pin 3 of blend door actuator. The current then flows
from pin 2 of blend door actuator to pin 16 of front A/C controller. This creates circuit for blend door actuator.
The current flows from pin 6 of blend door actuator to pin 4 of front A/C controller. This emits the blend actuator
signal to front A/C controller.
The current flows through pin 15 of front A/C controller to pin 3 of mode door actuator. The current then flows
from pin 2 of mode door actuator to pin 16 of front A/C controller. This creates circuit for mode door actuator.
The current flows from pin 6 of mode door actuator to pin 3 of front A/C controller. This emits the mode
actuator signal to front A/C controller.
Front Blower Control

The current flows through A/C cut relay to pin 86 of front heater relay R11, through coil, the power is ground at
pin 85 of front heater relay R11. The coil of front heater relay R11 creates a magnetic field, and switch is
activated. The current flows through fusible link FL2 in engine room junction box, to pin 87 of front heater relay
R11, through switch, to pin 2 of front blower motor, through motor, the current then flows from pin 1 of front
blower motor to pin 1 of front blower motor resistor and pin 4 of blower switch.
When the blower switch is in LO position, the current flows from pin 1 of front blower motor, pin 1 of front
blower motor resistor, through resistor, the current then flows from pin 4 of front blower motor resistor, to pin 6
of blower switch. The power is ground at pin 3 of blower switch.
When the blower switch is in M1 position, the current flows from pin 1 of front blower motor, pin 1 of front
When the blower switch is in HI position, the current flows from pin 1 of front blower motor, pin 4 of blower
switch. The power is ground at pin 3 of blower switch.
A/C Amplifier
The current flows through A/C cut relay, to pin 1 and pin 2 of A/C clutch relay, through coil, to pin 2 of dual
function pressure switch, through HI/LO switch, the current flows from pin 4 of dual function pressure switch to
pin 15 of A/C amplifier. The power is ground by A/C amplifier. The coil of A/C clutch relay creates a magnetic
field, and switch is activated. The current then flows from pin 4 of A/C clutch relay to pin 1 of A/C clutch field
coil. The power is ground by A/C clutch field coil. This enables A/C clutch to operate.
The data communication transmits from pin 8 and pin 10 of A/C amplifier to pin 39 and pin 46 of engine control
module. This emits A/C operation signal.
The current flows from pin 16 of A/C amplifier to pin 2 of front intake sensor. The current then flows from pin 1
of front intake sensor to pin 4 and pin 12 of A/C amplifier. This emits the front intake signal to A/C amplifier.
The current flows from pin 16 of A/C amplifier to pin 1 of rear intake sensor. The current then flows from pin 2
of rear intake sensor to pin 7 of A/C amplifier. This emits the rear intake signal to A/C amplifier.
The current flows from pin 2 of rear intake sensor to pin 2 of rear temperature control switch. The current then
flows from pin 1 of rear temperature control switch to pin 17 of A/C amplifier. This emits the rear intake adjust
signal to A/C amplifier.
When rear evaporator blower switch is in operation, press rear A/C switch (front control), the current through
71
pin 2 of A/C amplifier to pin 6 of rear A/C switch (front control), through switch, the current flows from pin 2 of
rear A/C switch (front control), to pin 4 of rear evaporator blower switch. The power is ground at pin 8 of rear
evaporator blower switch. This emits rear A/C switch input signal to A/C amplifier. 71
The current flows through A/C cut relay to pin 2 of rear evaporator solenoid, through solenoid, the current then
flows from pin 1 of rear evaporator solenoid to pin 9 of A/C amplifier. The refrigerant enter into rear A/C line is
controlled by A/C amplifier.
Rear A/C Control

The current flows through A/C cut relay to pin 5 of rear evaporator motor relay, through coil, to pin 6 of rear A/
C switch (front control). When rear evaporator blower switch is in operation, press rear A/C switch (front
control), the current flows from pin 2 of rear A/C switch (front control), to pin 4 of rear evaporator blower switch.
The power is ground at pin 8 of rear evaporator blower switch. The coil of rear evaporator motor relay creates
a magnetic field, and switch is activated. The current flows through fusible link FL5 in engine room junction
box, to pin 1 of rear evaporator motor relay, and then to two 7.5A fuses. The current flows from pin 2 of rear
evaporator motor LH and pin 2 of rear evaporator motor RH, through motor, to pin 6 of rear evaporator blower
switch and pin 1 of rear evaporator resistor:
When rear evaporator motor operation in LO, the current flows from pin 1 of rear evaporator motor LH and pin
1 of rear evaporator motor RH, to pin 1 of rear evaporator resistor. The power is ground at pin 3 of rear
evaporator resistor.
When rear evaporator motor operation in M, the current flows from pin 1 of rear evaporator motor LH and pin 1
of rear evaporator motor RH, to pin 1 of rear evaporator resistor. Through resistor, the current flows from pin 2
of rear evaporator resistor to pin 1 of rear evaporator blower switch. The power is ground at pin 8 of rear
evaporator blower switch.
When rear evaporator motor operation in HI, the current flows from pin 1 of rear evaporator motor LH and pin
1 of rear evaporator motor RH, to pin 6 of rear evaporator blower switch. The power is ground at pin 8 of rear
Service Hints
• C005 A/C Cut Relay
3 – 4: Open with the ignition switch at ST position.
• C010 A/C Clutch Relay
2 – 4: Closed with the A/C clutch relay in operation.
• C009 Rear Evaporator Motor Relay
1 – 2: Closed with the rear evaporator motor relay in operation.
Parts Location

C008 Instrument Panel Wire Harness F301 Rear Evaporator Wire Harness


A101 C106

C116 Q104

E102 C102

E103 C103

F102 C111

F105 F401

G103 K101

Q101 G102
Ground Points


MANUAL AIR CONDITIONER CONTROL - WITH 4G63/4G64 ENGINE
71
71
71
71
System Description
The current then flows from pin 3 of A/C cut relay, to pin 1 of front A/C controller, pin 86 of front heater relay
R11, pin 3 and pin 13 of A/C amplifier, pin 1 and pin 2 of A/C clutch Relay, pin 2 of rear evaporator solenoid
and pin 5 of rear evaporator motor relay. System is then powered.
normal.
Front A/C Control

controller.
amplifier.
motor, the current then flows from pin 7 of fresh/recirculation door actuator to pin 4 of front A/C controller. This
enables fresh/recirculation door actuator to operate.

A/C Control
The data communication transmits from pin 8 and pin 10 of A/C amplifier to pin 39 and pin 46 of engine control
module. This emits A/C operation signal.
evaporator blower switch. This emits rear A/C switch input signal to A/C amplifier.
71
Rear A/C Control
71
Service Hints
Parts Location



A101 C106

C116 Q104

E102 C102

E103 C103

F102 C111

F105 F401

G103 K101

Q101 G102
Ground Points


MANUAL AIR CONDITIONER CONTROL - WITH BJ493ZQ3 ENGINE
71
71
71
71
System Description
The current flows through fusible link FL6 in engine room junction box, to pin 2 of main relay R2, to fuse F20 in
body junction box, and then to the following circuits:
a. The circuit flows through pin 1 of front A/C controller. Front A/C controller is then powered.
b. The circuit flows through pin 13 of A/C amplifier. A/C amplifier is then powered.
The current then flows from pin 3 of A/C cut relay, to pin 86 of front heater relay R11, pin 3 of A/C amplifier, pin
1 and pin 2 of A/C clutch Relay, pin 2 of rear evaporator solenoid and pin 5 of rear evaporator motor relay.
normal.
Front A/C Control

controller.
amplifier.
motor, the current then flows from pin 7 of fresh/recirculation door actuator to pin 4 of front A/C controller. This
enables fresh/recirculation door actuator to operate.

A/C Amplifier
The data communication transmits from pin 8 and pin 10 of A/C amplifier to pin K54 and pin K68 of engine
control module. This emits A/C operation signal.
evaporator blower switch. This emits rear A/C switch input signal to A/C amplifier.
71
Rear A/C Control 71

Service Hints
Parts Location




A101 C106

A102 C108

A104 C107

C122 Q107

F102 C111

F105 F401

G103 K101

Q101 G102

Q106 C121
Ground Points


REAR HEATER CONTROL - SWITCH LOCATED IN MIDDLE PLATFORM
71
71
System Description
Rear Heater Switch (Front Control) and Rear Heater Switch (Rear Control)
When ignition switch in ON/ST, the current flows through fuse F2 in body junction box, to pin 2 of rear heater
relay 1 R10 and pin 85 of rear heater relay 2 R9, through two coil, to pin 2 of rear heater switch (front control)
and pin 2 of rear heater switch (rear control). Any switch operates, the coil of rear heater relay 1 R10 and the
coil of rear heater relay 2 R9 create a magnetic field, and switch is activated. This enables rear heater relay 1
R10 and rear heater relay 2 R9 to operate.
Rear Heater Blower Motor

The current flows through fusible link FL1 in engine room junction box, to fuse F7 in body junction box, to pin 3
of rear heater relay 1 R10. When rear heater switch (front control) and rear heater switch (rear control) are in
operation, the rear heater relay 1 R10 is then in operation; the current then flows from rear heater relay 1 R10,
to pin 1 of rear heater blower motor, through motor, the rear heater blower motor in operation by resistor:
a. The current flows from pin 2 of rear heater blower motor, to pin 6 of rear heater blower switch. The power is
ground at pin 1 of rear heater blower switch. This enables rear heater blower motor in HI operation.
b. The current flows from pin 4 of rear heater blower motor, to pin 3 of rear heater blower switch. The power is
ground at pin 1 of rear heater blower switch. This enables rear heater blower motor in M operation.
c. The current flows from pin 3 of rear heater blower motor, to pin 4 of rear heater blower switch. The power is
ground at pin 1 of rear heater blower switch. This enables rear heater blower motor in LO operation.
Water Valve
When ignition switch is ON/ST, the current flows through fuse F2 in body junction box, to pin 4 of A/C cut relay,
through switch, to pin 3 of A/C cut relay, to pin 1 of water valve. The current then flows from pin 2 of water
valve to pin 30 of rear heater relay 2 R9. The power is ground at pin 87a of rear heater relay 2 R9. This
enables water valve to operate.
When rear heater switch (front control) and rear heater switch (rear control) are in operation, the rear heater
relay 2 R9 is in operation; the switch of rear heater relay 2 R9 is open. The water valve is out of power.
When ignition switch is ST, the current flows through fuse F16 in body junction box, to pin 2 of A/C cut relay.
The power is ground at pin 1 of A/C cut relay. The coil of A/C cut relay then creates a magnetic field, and
switch is open. A/C system is then out of power, and ensure starting system operates in normal.
Service Hints
3 – 4: Open with the A/C cut relay in operation.
Parts Location

A301 Engine Room Wire Harness L008 Chassis Wire Harness LH

A102 C108

C101 L101

C115 Q103
71
Ground Points 71

REAR HEATER CONTROL - SWITCH LOCATED IN SIDE WALL LH

System Description
Rear Heater Switch (Front Control) and Rear Heater Switch (Rear Control)
When ignition switch in ON/ST, the current flows through fuse F2 in body junction box, to pin 2 of rear heater 71
relay 1 R10 and pin 85 of rear heater relay 2 R9, through two coil, to pin 2 of rear heater switch (front control)
and pin 2 of rear heater switch (rear control). Any switch operates, the coil of rear heater relay 1 R10 and the
coil of rear heater relay 2 R9 create a magnetic field, and switch is activated. This enables rear heater relay 1 71
R10 and rear heater relay 2 R9 to operate.
Rear Heater Blower Motor

The current flows through fusible link FL1 (or FL6) in engine room junction box, to fuse F7 in body junction
box, to pin 3 of rear heater relay 1 R10. When rear heater switch (front control) and rear heater switch (rear
control) are in operation, the rear heater relay 1 R10 is then in operation; the current then flows from rear
heater relay 1 R10, to pin 1 of rear heater blower motor, through motor, the rear heater blower motor in
operation by resistor:
a. The current flows from pin 2 of rear heater blower motor, to pin 6 of rear heater blower switch. The power is
ground at pin 1 of rear heater blower switch. This enables rear heater blower motor in HI operation.
b. The current flows from pin 4 of rear heater blower motor, to pin 3 of rear heater blower switch. The power is
ground at pin 1 of rear heater blower switch. This enables rear heater blower motor in M operation.
c. The current flows from pin 3 of rear heater blower motor, to pin 4 of rear heater blower switch. The power is
ground at pin 1 of rear heater blower switch. This enables rear heater blower motor in LO operation.
Water Valve
When ignition switch is ON/ST, the current flows through fuse F2 in body junction box, to pin 4 of A/C cut relay,
through switch, to pin 3 of A/C cut relay, to pin 1 of water valve. The current then flows from pin 2 of water
valve to pin 30 of rear heater relay 2 R9. The power is ground at pin 87a of rear heater relay 2 R9. This
enables water valve to operate.
When rear heater switch (front control) and rear heater switch (rear control) are in operation, the rear heater
relay 2 R9 is then in operation; the switch of rear heater relay 2 R9 is open. The water valve is out of power.
When ignition switch is ST, the current flows through fuse F16 in body junction box, to pin 2 of A/C cut relay.
The power is ground at pin 1 of A/C cut relay. The coil of A/C cut relay then creates a magnetic field, and
switch is open. A/C system is then out of power, and ensure starting system operates in normal.
Service Hints
3 – 4: Open with the A/C cut relay in operation.
Parts Location

A301 Engine Room Wire Harness L008 Chassis Wire Harness LH

A102 C108

C101 L101

C115 Q103

C122 Q107

G104 H101

Q105 G105
Ground Points


OUTSIDE MIRROR AND REAR WINDOW DEFROSTER

OUTSIDE MIRROR AND REAR WINDOW DEFROSTER - WITH 4G63/4G64
ENGINE 71
71
System Description
Outside Mirror Defroster
When ignition switch is ON/ST, the current flows through fuse F1 in body junction box, to pin 9 of outside mirror
LH and pin 9 of outside mirror RH. The current then flows from pin 8 of outside mirror LH and pin 8 of outside
mirror RH to pin 3 of outside mirror defrost switch. When pressing the outside mirror defrost switch, the power
is ground at pin 6 of outside mirror defrost switch. This enables heater strip of outside mirror to operate.
Rear Window Defroster

When ignition switch is ON/ST, the current flows through fuse F1 in body junction box, to pin 2 of defrost relay
R8, to pin 3 of rear window defrost switch. When pressing the rear window defrost switch, the power is ground
at pin 6 of rear window defrost switch; the coil of defrost relay R8 creates a magnetic field, and switch is
activated; the current flows through fusible link FL6 in engine room junction box, to fuse F20 in body junction
box, to pin 5 of defrost relay R8. The current then flows from pin 3 of defrost relay R8, and then to following
circuits:
Equipped with rod antenna: The current flows through rear window defrost grid, and the power is ground by
heater strip of rear window defrost grid. This enables rear window defroster to operate.
Equipped with glass antenna: The current flows through pin 4 of antenna amplifier, to pin 3 of antenna
amplifier, and then to rear window defrost grid. The power is ground by heater strip of rear window defrost grid.
This enables rear window defroster to operate.
Service Hints
• C019 Outside Mirror Defrost Switch
3 – 6: Closed with the outside mirror defrost switch in operation.
• C022 Rear Window Defrost Switch
3 – 6: Closed with the rear window defrost switch in operation.
Parts Location

F006 Roof Wire Harness

A104 C107

C104 M101

C112 N102

F101 C110

F103 I102

I101 F104
71
I103 J101
(Sliding Door LH) 71
Ground Points

C214 Right Side of the Instrument Panel F205 Above Rear Window RH

OUTSIDE MIRROR AND REAR WINDOW DEFROSTER - WITH BJ493ZQ3

ENGINE
System Description
Outside Mirror Defroster
When ignition switch is ON/ST, the current flows through fuse F1 in body junction box, to pin 9 of outside mirror 71
LH and pin 9 of outside mirror RH. The current then flows from pin 8 of outside mirror LH and pin 8 of outside
mirror RH to pin 3 of outside mirror defrost switch. When pressing the outside mirror defrost switch, the power
is ground at pin 6 of outside mirror defrost switch. This enables heater strip of outside mirror to operate. 71
Rear Window Defroster

When ignition switch is ON/ST, the current flows through fuse F1 in body junction box, to pin 2 of defrost relay
R8, to pin 3 of rear window defrost switch. When pressing the rear window defrost switch, the power is ground
at pin 6 of rear window defrost switch; the coil of defrost relay R8 creates a magnetic field, and switch is
activated; the current flows through fuse F27 in engine room junction box, to pin 5 of defrost relay R8. The
current then flows from pin 3 of defrost relay R8, and then to following circuits:
Equipped with rod antenna: The current flows through rear window defrost grid, and the power is ground by
heater strip of rear window defrost grid. This enables rear window defroster to operate.
Equipped with glass antenna: The current flows through pin 4 of antenna amplifier, to pin 3 of antenna
amplifier, and then to rear window defrost grid. The power is ground by heater strip of rear window defrost grid.
This enables rear window defroster to operate.
Service Hints
• C019 Outside Mirror Defrost Switch
3 – 6: Closed with the outside mirror defrost switch in operation.
• C022 Rear Window Defrost Switch
3 – 6: Closed with the rear window defrost switch in operation.
Parts Location


A104 C107

C104 M101

C112 N102

F101 C110

F103 I102

I101 F104

I103 J101
(Sliding Door LH)
Ground Points

C214 Right Side of the Instrument Panel F205 Above Rear Window RH

COMMUNICATION SYSTEM
HORN
71
71
System Description
Without Driver Airbag
The current flows through fuse F25 in engine room junction box, to pin 2 and pin 5 of horn relay R6, through
coil, to pin 18 of combination switch. When pressing the horn switch, the power is ground by combination
switch. The coil of horn relay R6 creates a magnetic field, and switch is activated. The current then flows from
pin 3 of horn relay R6, to pin 1 of horn LH and pin 1 of horn RH. The power is ground by horn. This enables
horn to operate.
With Driver Airbag

The current flows through fuse F25 in engine room junction box, to pin 2 and pin 5 of horn relay R6, through
coil, to pin 18 of combination switch, and then to pin 1 of clock spring C046. The current flows from pin 1 of
clock spring C047, to pin 1 of horn switch. When pressing the horn switch, the power is ground by horn switch.
The coil of horn relay R6 creates a magnetic field, and switch is activated. The current then flows from pin 3 of
horn relay R6, to pin 1 of horn LH and pin 1 of horn RH. The power is ground by horn. This enables horn to
operate.
Service Hints
• A009 Horn LH
1 – 2: Approx. 2Ω
• A010 Horn RH
1 – 2: Approx. 2Ω
Parts Location


A104 C107
Ground Points

A203 Right Side of the Engine Room
REVERSE RADAR CONTROL
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71
System Description
switch. When shift lever in “R” position, the current flows from pin 1 of back-up lamp switch to pin 1 of reverse
radar controller. The reverse radar controller is then powered.
The current flows from pin 7 of reverse radar controller to pin 2 of reverse radar sensor LH. The power is
ground at pin 1 of reverse radar sensor LH. This detects the obstacle in left side.
The current flows from pin 8 of reverse radar controller to pin 2 of reverse radar sensor MID. The power is
ground at pin 1 of reverse radar sensor MID. This detects the obstacle in middle.
The current flows from pin 15 of reverse radar controller to pin 2 of reverse radar sensor RH. The power is
ground at pin 1 of reverse radar sensor RH. This detects the obstacle in right side.
The data communication transmits from pin 5 and pin 13 of reverse radar controller to pin 6 and pin 5 of
combined display. This will display the information of reverse radar controller on the combined display.
Service Hints
• E011 Back-up Lamp Switch
Parts Location


C116 Q104

C118 C501

E102 C102

G104 H101
H102 D101

Q101 G102
Ground Points

COMBINED DISPLAY
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71
System Description
When ignition switch is ACC/ON, the current flows through fuse F14 in body junction box, pin 13 of combined
display. The combined display is then powered.
The current flows from pin 3 of odometer sensor, to pin 4 of combined display. This emits the vehicle speed
signal to combined display.
The current flows from pin 1 of combined display, to pin 1 of in-vehicle temperature sensor. The power is
ground at pin 2 of in-vehicle temperature sensor. This checks temperature in vehicle.
The data communication transmits from pin 5 and pin 6 of combined display to pin 13 and pin 5 of reverse
radar controller. This will display the information of reverse radar controller on the combined display.
Parts Location

C401 Combined Display Wire Harness Q005 Front Body Wire Harness

C115 Q103

C118 C501

E102 C102
Ground Points


POWER SOCKET
71
71
System Description
Power Point Socket (Cigarette Lighter)
When ignition switch is ACC/ON, the current flows through fuse F15 in body junction box, pin 1 of power point
socket (cigarette lighter). When pressing the cigarette lighter, the power is ground at pin 2 of power point
socket (cigarette lighter). This enables cigarette lighter to operate.
12V Power Point Socket

When ignition switch is ACC/ON, the current flows through fuse F15 in body junction box, pin 1 of 12V power
point socket. When the power plug of electric equipment inserted to power socket, the power is ground at pin
2 of 12V power point socket. This enables 12V power point to operate.
Parts Location

Ground Points

SLIDING ROOF
71
71
System Description
When ignition switch is ON/ST, the current flows through fuse F6 in body junction box, pin 1 of sliding roof
control module. The sliding roof control module is then powered.
When the sliding roof control switch in Open position, the current flows from pin 3 of sliding roof control module
to pin 3 of sliding roof control switch. The power is ground at pin 2 of sliding roof control switch; the current
flows from pin 8 of sliding roof control module to pin 1 of sliding roof control motor, through motor, the current
then flows from pin 4 of sliding roof control motor, to pin 5 of sliding roof control module. This enables sliding
roof to open.
When the sliding roof control switch in Close position, the current flows from pin 2 of sliding roof control
module to pin 1 of sliding roof control switch. The power is ground at pin 2 of sliding roof control switch; the
current flows from pin 5 of sliding roof control module to pin 4 of sliding roof control motor, through motor, the
current then flows from pin 1 of sliding roof control motor, to pin 8 of sliding roof control module. This enables
sliding roof to close.
The current flows from pin 7 of sliding roof control module to pin 3 of sliding roof control motor. When limit
switch (Open) closed, the power is ground at pin 2 of sliding roof control motor. This enables sliding roof to
stop.
The current flows from pin 6 of sliding roof control module to pin 6 of sliding roof control motor. When limit
switch (Close) closed, the power is ground at pin 5 of sliding roof control motor. This enables sliding roof to
stop.
Service Hints
• F005 Sliding Roof Control Switch
1 – 2: Closed with the sliding roof control switch in Close position.
2 – 3: Closed with the sliding roof control switch in Open position.
Parts Location

C301 Instrument Panel Wire Harness F005 Roof Wire Harness
F003 Roof Wire Harness F007 Roof Wire Harness

F101 C110
Ground Points

IGNITION KEY POSITION REMIND CONTROLLER
71
71
System Description
The current flows through fuse F26 in engine room junction box, to following circuits:
a. The current flows through pin 6 of ignition key position remind controller. The ignition key po sition remind
controller is then powered.
b.The current flows through pin 2 of ignition position switch, to pin 1 of ignition position switch, and to pin 4 of
ignition key position remind controller. This checks the position of ignition key in cylinder.
When parking lamp relay in operation, the current flows through fusible link FL1 (or FL6) in engine room
junction box, to pin 5 of parking lamp relay R4, and then to fuse F19 in body junction box, to pin 3 of ignition
key position remind controller; when removed the ignition key, the ignition key position remind controller will
sound a warning chime.
When front door LH is opened, the current flows from pin 2 of ignition key position remind controller to pin 1 of
front door ajar switch LH. The power is ground by front door ajar switch LH; when the ignition key in cylinder,
the ignition key position remind controller will sound a warning chime.
When the ignition key removed, the current flows from pin 5 of ignition key position remind controller to pin 1 of
ignition keyhole illumination. The power is ground at pin 2 of ignition keyhole illumination. This enables ignition
keyhole to illuminate for 15 seconds.
Service Hints
• C029 Ignition Position Switch
1 – 2: Closed with the ignition key in cylinder.
• L001 Front Door Ajar Switch LH
1 – Ground: Closed with the front door LH open.
Parts Location


A101 C106

A104 C107

C101 L101
Ground Points

POWER MIRROR
71
71
System Description
When ignition switch is ACC/ON, the current flows through fuse F14 in body junction box, pin 6 of outside
mirror remote control switch. System is then powered.
Outside Mirror Opened

The current flows from pin 6 to pin 8 of outside mirror remote control switch, then to pin 1 of outside mirror LH
and pin 1 of outside mirror RH, through motor to pin 10 of outside mirror LH and pin 10 of outside mirror RH.
The current then flows from pin 3 of outside mirror remote control switch to ground at pin 4 of outside mirror
remote control switch.
Outside Mirror Closed

The current flows from pin 6 to pin 3 of outside mirror remote control switch, then to pin 10 of outside mirror LH
and pin 10 of outside mirror RH, through motor to pin 1 of outside mirror LH and pin 1 of outside mirror RH.
The current then flows from pin 8 of outside mirror remote control switch, to ground at pin 4 of outside mirror
remote control switch.
Outside Mirror LH (Up/Down)

The current flows from pin 6 to pin 1 of outside mirror remote control switch, to pin 4 of outside mirror LH,
through motor, the current then flows from pin 3 of outside mirror LH, to pin 3 of outside mirror remote control
switch. The power is ground at pin 4 of outside mirror remote control switch. This enables outside mirror LH to
go up.
go down.
Outside Mirror RH (Up/Down)

The current flows from pin 6 to pin 2 of outside mirror remote control switch, to pin 4 of outside mirror RH,
through motor, the current then flows from pin 3 of outside mirror RH, to pin 3 of outside mirror remote control
switch. The power is ground at pin 4 of outside mirror remote control switch. This enables outside mirror RH to
go up.
go down.
Outside Mirror LH (Left/Right)

turn left.
turn right.
Outside Mirror RH (Left/Right)

turn left.
switch. The power is ground at pin 4 outside mirror remote control switch. This enables outside mirror RH to
turn right.
Parts Location

71
M005 Front Door Wire Harness RH N003 Front Door Wire Harness LH 71

C105 N104

C113 M103

C120 N103
Ground Points

WIPER AND WASHER

System Description
When ignition switch is ON/ST, the current flows through fuse F4 in body junction box, to pin 17 of combination
switch, pin 1 of front washer pump, pin 1 of rear washer pump and pin 10 of multi-function controller (3-in-1)
71
C002. System is then powered.
Front Wiper Switch LO 71

When the front wiper switch of combination switch is in LO position, the current flows from pin 17 to pin 7 of
combination switch, to pin 1 of front wiper motor and through wiper motor to ground at pin 5 of front wiper
motor. This enables front wiper to operate at low speed.
Front Wiper Switch HI

When the front wiper switch of combination switch is in HI position, the current flows from pin 17 to pin 8 of
combination switch, and then to pin 4 of front wiper motor and through wiper motor to ground at pin 5 of front
wiper motor. This enables front wiper to operate at high speed.
Front Wiper Switch INT

When the front wiper switch of combination switch is set INT, the current flows from pin 17 of combination
switch, pass through wiper intermittent mechanism to pin 7 of combination switch to pin 1 of front wiper motor.
The power is ground at pin 5 of front wiper motor. This enables front wiper to operate in the intermittent mode.
Front Washer switch ON

When the front washer switch is in ON position, the current flows from pin 2 of front washer pump to pin 11 of
combination switch, and then to ground at pin 2 of combination switch. This enables front washer to function.
Rear Wiper Switch WASH1

When the rear wiper switch is in WASH1 position, the current flows from pin 2 of rear washer pump to pin 12 of
combination switch, and then to ground at pin 2 of combination switch. This enables rear wiper to function.
Rear Washer Switch ON

When the rear washer switch of combination switch is set ON, the current flows from pin 4 of multi-function
controller (3-in-1), pin 10 of the combination switch. Power is ground at pin 2 of combination switch. The multi-
function controller (3-in-1) is then activated. Current then pass through pin 13 of multi-function controller (3-in-
1) to pin 4 of rear wiper motor. The power is ground at pin 3 of rear wiper motor. This enables rear wiper to
function.
Rear Washer Switch INT

When the rear washer switch of combination switch is set INT, the current flows from pin 5 of multi-function
controller (3-in-1), pin 13 of the combination switch. Power is ground at pin 2 of combination switch. The multi-
function controller (3-in-1) is then activated. Current then pass through pin 13 of multi-function controller (3-in-
1) to pin 4 of rear wiper motor. Power is ground at pin 3 of rear wiper motor. This enables rear wiper to operate
in intermittent mode.
Rear Washer Switch WASH2

When the rear washer switch is in WASH2 position, the current flows from pin 2 of rear washer pump to pin 12
of combination switch, and then to ground at pin 2 of combination switch. This enables rear washer function.
When the rear washer switch is set ON, the current flows from pin 4 of multi-function controller (3-in-1), to pin
10 of the combination switch, Power is ground at pin 2 of combination switch. The multi-function controller (3-
in-1) is then activated. Current then pass through pin 13 of multi-function controller (3-in-1) to pin 4 of rear
wiper motor. The power is ground at pin 3 of rear wiper motor. This enables rear wiper to function.
Parts Location



F101 C110

I101 F104

I103 J101
(Sliding Door LH)
Ground Points

AUDIO
71
71
Service Hints
• C032 Audio
4 - Ground: Approx. 12 V
7 - Ground: Approx.12 volts with the ignition switch at ACC/ON position.
8 - Ground: Always continuity
• F006 Antenna Amplifier (with Glass Antenna)
2 - Ground: Approx. 12 V
• G002 Rear Speaker RH
1 - 2: Approx. 4 Ω
• H002 Rear Speaker LH
1 - 2: Approx. 4 Ω
• M003 Front Speaker RH
1 - 2: Approx. 4 Ω
• N005 Front Speaker LH
1 - 2: Approx. 4 Ω
Parts Location


A104 C107

C105 N104

C113 M103

C116 Q104
(Under Middle Panel)

F101 C110
G104 H101 Rear Body Wire Harness RH & Rear Body Wire Harness LH (Under D-Pillar)

Q101 G102
(Inside Front Step Board Cover RH)
Ground Points

WIRING - CONNECTOR VIEWS 71-173
CONNECTOR VIEWS
A - ENGINE ROOM WIRE HARNESS
71
71
A002 Front Wheel Speed Sensor LH A006　Front Combination Lamp LH

Pin Color Function Qualifier Pin Color Function Qualifier
1 B Left Front + 1 G-B Input
2 W Left Front - 2 W-B Ground
A003 Brake Fluid Level Sensor

Pin Color Function Qualifier
1 G-W Signal
2 W-B Ground
A007 Front Combination Lamp LH
1 G-R Parking Lamp
2 R-Y High Beam

A004 Front Fog Lamp LH 3 R-L Low Beam
Pin Color Function Qualifier 4 W-B Ground
1 LG Front Fog Lamp Relay 5 R Headlamp
2 W-B Ground 6 - -
A005 Engine Coolant Fluid Level Sensor A008 Front Combination Lamp RH
1 B-O Input 1 G-Y Input
2 V-W Output 2 W-B Ground

71-174 WIRING - CONNECTOR VIEWS
A009 Horn LH A015 Preheat Controller

1 B Power Supply 1 W Power Supply
2 W-B Ground
A010 Horn RH A013 Front Combination Lamp RH

1 B Power Supply 1 G-R Parking Lamp
2 W-B Ground 2 R-Y High Beam
3 R-L Low Beam
4 W-B Ground
5 R-G Headlamp
6 - -
A011 Front Fog Lamp RH
1 LG Front Fog Lamp
2 W-B Ground
A012 Dual Function Pressure Switch A014 Preheat Controller
1 L A/C Pressure 1 W-B Ground
2 L-O A/C Clutch Field Coil 2 G-Y Input
3 W-B Ground 3 W-R Power - Main Relay
4 R-W A/C Amplifier 4 - -
5 Y-G Output
71
A016 Oil Water Separator A017 Heated Switch 71

1 W-B Ground 1 B-O Input
2 Y-L Oil Water Separator 2 W-B Ground
3 W-R Main Relay
A018 Heater
1 Y-G Heater Relay
2 W-B Ground
A101 to Instrument Panel Wire Harness

1 G-B - 14 L-B -
2 G-Y - 15 W -
3 B - 16 R-W -
4 W - 17 L-O -
5 R - 18 L -
6 R-G - 19 R-W -
7 W - 20 W - 4G Series
8 LG - 20 Y-R - BJ Series
9 R-B - 21 B -
10 R - 22 R-B -
11 R-L - 23 LG -
12 R-Y - 24 L -
13 G-W -
A102 to Instrument Panel Wire Harness A103 to Fan Wire Harness

1 - - 4G Series 1 LG -
1 R - BJ Series 2 L -
2 W - 3 W-B -
3 B - 4G Series 4 W-B -
3 - - BJ Series
A104 to Instrument Panel Wire Harness

1 R - 11 B-O - BJ Series
2 W-R - 12 W-R -
3 R-B - 13 G-B -
4 B-W - 4G Series 14 W-L -
4 Y-L - BJ Series 15 B-O - 4G Series
5 Y-G - 4G Series 15 G-Y - BJ Series
5 G-R - BJ Series 16 G-R -
6 G-R - 4G Series 17 B-R -
6 L-G - BJ Series 18 V-W -
7 G-R - 19 - - 4G Series
8 B-W - 19 W - BJ Series
9 L-R - 20 - - 4G Series
10 B - 20 Y-G - BJ Series
11 B-Y - 4G Series
71
71
A105 to Engine Room Sub-harness A411 Starter Motor

(with BJ493ZQ3 Engine)
1 B-R -
1 Y-R -
2 G-R -
3 B-O -
4 B -
A401 Battery Positive Terminal A412 Starter Motor

B B-R - 1 B-R -
B - FAN WIRE HARNESS
B001 Main Fan Motor B101 to Engine Room Wire Harness

1 L-O High Speed (HI) 1 LG -
2 L-B Low Speed(LO) 2 L -
3 W-B Ground 3 W-B -
4 W-B -
B002 Secondary Fan Motor

1 L-W High Speed (HI)
2 W-B Ground
71
71
C001 Rear Fog Lamp Switch C003 Multi-function Controller (3-in-1)

1 W-B Ground 1 R Power Supply
2 - - 2 R-Y Fog Light Indicator
3 W-B Ground 3 R-L Rear Fog Lamp Switch
4 R-Y Working Light 4 LG-Y Signal
5 G Switch Illumination 5 P Signal
6 R-L Input 6 R-W Headlamp Switch
7 R-B Front Fog Light Switch
8 G Parking Lamp
C002 Multi-function Controller (3-in-1)

C005 A/C Cut Relay
9 G-R Input
10 L Power Supply
1 W-B Ground
11 W-B Ground
2 B Input
12 G-W Switch
3 R-Y Power Supply
13 L-B Output
4 R-L Input
14 P-L Output
C006 Front Blower Motor Resistor
C004 Stop Lamp Switch Pin Color Function Qualifier

(with 4G63/4G64 Engine) 1 W-R Input
Pin Color Function Qualifier 2 L-O Mid Speed (M1)
1 G-W Braking 3 R Mid Speed (M2)
2 W Power Supply 4 L-R Low Speed (LO)
C007 Front Intake Sensor C009 Rear Evaporator Motor Relay

1 R Temperature 1 W -
2 W-R Ground 2 L-R -
3 L-R -
4 W-B -
5 R-Y -
C010 A/C Clutch Relay

1 R-Y - C011 Capacitance
2 R-Y - Pin Color Function Qualifier
3 L-O - 1 B-R -
4 B-O - 2 W-B -
C008 A/C Amplifier

1 - - 10 Y-L ACT 4G Series
2 L-R Rear A/C Switch 10 W-R ACT BJ Series
3 R-Y Power Supply 11 Y-G Front A/C Switch
4 R Front Intake Sensor 12 R Front Intake Sensor
5 - - 13 R-Y Power Supply
6 W-B Ground 14 - -
7 O Rear Intake Sensor 15 R-W A/C Clutch Relay
8 L-R ACI 4G Series 16 W-R Ground
8 W ACI BJ Series 17 LG Control Switch
9 Y-G Solenoid Control 18 - -

71
C012 Diode C015 Front Wheel Speed Sensor RH
71
1 W-R - 1 B Right Front -
2 W-L - 2 W Right Front +
C014 Front Wiper Motor C016 Accelerator Sensor

1 L-B Signal 1 G-B 5V Power Supply
2 L-W Signal 2 L-R Signa
3 L Ignition 3 BR Ground
4 L-O Input
5 W-B Ground
C017 Front A/C Controller (Auto)

1 Y-G Front A/C Switch 11 W-B Ground
2 V-W Signal - Blower Motor 12 - -
3 LG-B Blend Door Actuator 13 G Illumination
4 LG Mode Door Actuator 14 W-B Ground
5 - - 15 L-B Power - Actuator
6 L-W Blend Door Actuator 2 16 L-Y Ground - Actuator
7 L-R Blend Door Actuator 1 17 - -
8 L Mode Door Actuator 1 18 B F/R Door Actuator 1
9 L-O Mode Door Actuator 2 19 W F/R Door Actuator 2
10 R-Y Power Supply 20 - -

C018 12V Power Point Socket C021 Power Point Socket

1 GR Power Supply 1 GR Power Supply
2 W-B Ground 2 W-B Ground
3 G Illumination 3 G Illumination
C019 Outside Mirror Defrost Switch C022 Rear Window Defrost Switch
2 - - 2 - -
3 L-Y Switch 3 L Power Supply
4 W-R Switch Working Light 4 R-B Switch Working Light
C020 Rear Heater Switch (Front Control) C023 Rear A/C Switch (Front Control)
2 Y-R Power Supply 2 R Output
3 R Output 3 - -
4 R-L Working Light 4 L-O Switch Working Light
6 W-B Ground 6 L-R Power Supply

71
C024 Blower Switch C026 Mode Door Actuator 71

1 R Mid Speed (M2) 1 - -
2 V-W Blower Motor 2 L-Y Ground - Actuator
3 W-B Ground 3 L-B Power - Actuator
4 W-R High Speed (HI) 4 - -
5 L-O Mid Speed (M1) 5 L-O Mode Door Actuator 2
6 L-R Low Speed (LO) 6 LG-B Mode Door Actuator
7 L Mode Door Actuator 1
C025 Blend Door Actuator C028 Ignition Keyhole Illumination

1 - - 1 G-R Illumination
2 L-Y Ground 2 W-B Ground
3 L-B Power - Actuator
4 - -
5 L-R Blend Door Actuator 1
6 LG Blend Door Actuator
7 L-W Blend Door Actuator 2
C027 Restraint Control Module

1 - - 16 - -
2 - - 17 - -
3 - - 18 - -

4 - - 19 - -
5 B-O Power Supply 20 - -
6 BR Ground 21 - -
7 B-Y Airbag Warning Light 22 - -
8 - - 23 - -
9 P-B Diagnostic K Line 24 - -
10 Y Airbag + 25 - -
11 Y-B Airbag - 26 - -
12 - - 27 Y Output - Crash
13 - - 28 - -
14 - - 29 - -
15 - - 30 - -
C029 Ignition Position Switch

1 W Ignition Position C031 Audio
2 W-L Power Supply Pin Color Function Qualifier
1 R Rear Speaker RH +
2 W Rear Speaker RH -
3 LG Front Speaker RH +
4 L Front Speaker RH -
C030 Clock Spring 5 P Front Speaker LH +
Pin Color Function Qualifier 6 V Front Speaker LH -
1 Y Airbag + 7 B Rear Speaker LH +
2 Y-B Airbag - 8 Y Rear Speaker LH -

71
C032 Audio C034 Hazard Switch 71

Pin Color Function Qualifier Qualifie
Pin Color Function
r
1 - -
1 - -
2 - -
2 G Illumination
3 - -
3 W-B Ground
4 R Power Supply
4 - -
5 V Antenna
5 G-B Turn Signal Indicator
6 G Illumination
6 G-Y Turn Signal Indicator
7 GR Ignition
7 G-R Signal Output - Ignition
8 BR Ground
8 W Power Supply
9 G-W Multifunction Controller
10 L-O Ignition
C033 Ignition Switch

ST B-W -
AM2 W-R -
IG2 B-R -
IG1 B-Y - C035 Electronic Clock

ACC L-R - Pin Color Function Qualifier
- - 1 W-B Ground
AM1 W - 2 R Power Supply
- - 3 G Illumination
C036 Front Washer Pump C037 Rear Washer Pump

1 L Ignition 1 L Ignition
2 L-Y Signal Input 2 LG Signal Input
C038 ABS Module

1 R Left Front - 14 Y-R EBD Warning Light
2 G Left Front + 15 Y-G ABS Warning Light
3 - - STOPPER 16 - - STOPPER
4 B-R Ignition 17 - - STOPPER
5 Y Left Rear + 18 G-W Signal - Braking
6 L Left Rear - 19 W Right Front +
7 P-B Diagnostic K Line 20 B Right Front -
8 W-B Ground 21 - - STOPPER
9 R Power Supply 22 LG Right Rear -
10 - - STOPPER 23 P Right Rear +
11 - - STOPPER 24 W-B Ground
12 - - STOPPER 25 B-R Power Supply
13 - - STOPPER
C039 Combination Switch (Wiper and Wahser Control)

1 - - 10 LG-Y Signal - Switch
2 W-B Ground 11 L-Y Front Washer Pump
3 - - 12 LG Rear Washer Pump
4 - - 13 P Signal Input
5 - - 14 - -
6 - - 15 - -
C039 Combination Switch (Wiper and Wahser Control)

7 L-B Signal Output 16 L-W Front Wiper Motor 71
8 L-O Signal Output 17 L Ignition
71
9 - - 18 G-R Horn Relay
C040 Combination Switch (Light Control)

1 G-B Turn Left 10 W-B Ground
2 G-W Input - Turn 11 R-B Front Fog Lamp Relay
3 G-Y Output - Turn 12 - -
4 - - 13 R-W Headlamp Relay
5 - - 14 G-B Parking Lamp Relay
6 - - 15 - -
7 R-Y High Beam 16 W-B Ground
8 R-W Headlamp Relay 17 R-L Low Beam
9 - -
C041 Reverse Radar Controller

1 B-R Power Supply 9 - -
2 - - 10 - -
3 - - 11 - -
4 - - 12 - -

5 W-L Calculagraph 13 Y Signal Output
6 - - 14 - -
7 P Radar Sensor LH 15 LG Radar Sensor RH
8 L Radar Sensor Mid 16 W-B Ground
C042 Ignition Key Position Remind Controller

1 W-B Ground 4 W Ignition Position
2 W-R Door Ajar Switch 5 G-R Illumination
3 R-G Illumination 6 B-Y Power Supply
C043 Multi-function Door Lock Controller (4-in-1)

1 L-Y Power Supply 10 R-B Signal - Vehicle Speed
2 G-R P/ W Motor FR (Up) 11 L Signal Output
3 R-L P/ W Motor FR (Down) 12 L-B Signal Output
4 R P/ W Motor FL (Up) 13 W-R Door Ajar Switch
5 G P/ W Motor FL (Down) 14 G-Y Turn Left
6 R Actuator (Open) 15 G-B Turn Right
7 G Actuator (Close) 16 Y RCM
8 W-B Ground 17 L-R Actuator FL (Open)
9 R-B Signal Input - Ignition 18 L-O Actuator FL (OClose)

71
C044 Double Diode C046 Fresh/Recirculation Door Actuator 71

1 W-R - 1 - -
2 R - 2 - -
3 R-W - 3 - -
4 - -
5 B F/R Actuator 1
6 - -
7 W F/R Actuator 2
C047 Front Blower Motor
1 W-R Front Blower Motor
2 L-R Front Heater Relay
C045 Instrument Cluster

1 R Door Ajar Switch 19 B-W Seat Belt Switch
2 V-W Fluid Level Signal 20 B-L Malfunction indicator 4G Series
3 BR Ground 20 R-Y Malfunction indicator BJ Series
4 - - 4G Series 21 V Fuel Level Sensor
4 R Main Relay BJ Series 22 G-B Signal Input - Turn Left
5 BR Ground 23 Y-G Temperature Indicator 4G Series
6 LG Front Fog Lamp 23 Y-B Temperature Indicator BJ Series
7 R-Y Rear Fog Lamp 24 G-Y Turn Right
8 - - 4G Series 25 R-G High Beam
8 L-W Preheat Indicator BJ Series 26 R-W Braking
9 L Oil Pressure Switch 27 R-B Vehicle Speed

10 Y-W Input -CKP Sensor 28 Y-R EBD Warning Light
11 R Power Supply 29 - - 4G Series
12 G Interior Lighting 29 R-L Vacuum Alarm BJ Series
13 R-B Ignition 30 - - 4G Series
14 Y-G ABS 30 G Oil Water Separator BJ Series
15 - - 31 V SVS Warning Light 4G Series
16 P-L Generator 31 - - BJ Series
17 B-Y SRS Airbag 4G Series 32 - - 4G Series
17 - - BJ Series 32 BR Ground BJ Series
18 - -
C050 Accelerator Pedal Positon Sensor

1 L-B Power - APP Sensor C052 Clutch Switch
2 L-Y Power - APP Sensor (with BJ493ZQ3 Engine)
3 BR Ground - APP Sensor Qualifie
Pin Color Function
r
4 V-W Signal - APP Sensor
1 - -
5 V-O Ground - APP Sensor
2 - -
6 L Signal - APP Sensor
3 W-R Power Supply
4 Y Output
C051 Stop Lamp Switch

1 W-R Power Supply C053 EGR Valve
2 B-Y Signal Output Pin Color Function Qualifier
3 W-R Power Supply 1 W-R Power Supply
4 GR Signal Output 2 W Input - EGR

71
71
C054 Cooling Fan Control Module C060 Front A/C Controller (Manual)
1 L-O Temperature 1 R-Y Power Supply
2 O Temperature 2 W-B Ground
3 - - 3 B F/R Door Actuator 1
4 R Ignition 4 W F/R Door Actuator 2
5 W Power Supply 5 G Illumination
6 W-R A/C Amplifier 6 Y-G Front A/C Switch
7 L Mid Pressure 7 - -
8 LG Fan Control (HI) 8 V-W Blower Motor
9 V-W Fan Control (LO)
10 - -
11 - -
12 W-B Ground
C061 Driver Airbag
1 Y Airbag +
2 Y-B Airbag -
C101 to Chassis Wire Harness LH

1 - - 11 BR -
2 GR-B - 12 V -
3 Y-R - 13 - -
C101 to Chassis Wire Harness LH

4 W-L - 14 - -
5 W-B - 15 - -
6 W-R - 16 - -
7 Y - 17 P -
8 L - 18 LG -
9 R-Y - 19 G -
10 R - 20 R -
C102 to Engine Control Wire Harness

1 B-Y - 11 Y-L -
2 B-Y - 12 R-B -
3 B-W - 13 - -
4 - - 14 LG -
5 - - 15 V-W -
6 R-B - 16 - -
7 Y-G - 17 B -
8 L - 18 L -
9 R-Y - 19 B-O -
10 - - 20 - -
71
71

1 R-Y - 11 Y-W -
2 L-R - 12 G-R -
3 - - 13 BR -
4 G - 14 L-R -
5 B-L - 15 V -
6 - - 16 W-L -
7 L-B - 17 B-O -
8 - - 18 - -
9 P-L - 19 - -
10 G-B - 20 V -
C104 to Front Door Wire Harness LH C105 to Front Door Wire Harness LH
1 G-B - 1 L-O -
2 W-R - 2 P-B -
3 L-Y - 3 V -
4 L-Y - 4 P -
5 L - 5 L-Y -
6 L-B - 6 LG-B -
7 R - 7 LG-R -
8 G - 8 Y -
C106 to Engine Room Wire Harness

1 G-B - 14 L-B -
2 G-Y - 15 W -
3 G - 16 R-W -
4 R - 17 L-O -
5 R - 18 L -
6 R-G - 19 R-W -
7 W - 20 W - 4G Series
8 LG - 20 Y-R - BJ Series
9 R-B - 21 B -
10 R - 22 R-B -
11 R-L - 23 LG -
12 R-Y - 24 V-W -
13 G-W -

1 R - 11 B-O - BJ Series
2 W-R - 12 W-R -
3 R-B - 13 G-B -
4 B-W - 4G Series 14 L-Y -
4 Y-L - BJ Series 15 B-O - 4G Series
5 R-Y - 4G Series 15 G-Y - BJ Series
5 P-L - BJ Series 16 G-R -


6 G-R - 4G Series 17 B-R - 71
6 L-G - BJ Series 18 V-W -
71
7 G-R - 19 W - 4G Series
8 B-W - 19 - - BJ Series
9 W-R - 20 - - 4G Series
10 B - 20 Y-G - BJ Series
11 B-Y - 4G Series
C108 to Engine Room Wire Harness C109 to Diagnosis Wire Harness

1 - - 1 R -
2 W - 2 W-L -
3 B - 3 W -
4 W-B -
5 W-B -
6 P-B -
7 P-B -
8 L-B -
C110 to Roof Wire Harness

1 R - 11 G -
2 W-R - 12 G-W -
3 V - 13 G-W -
4 L - 14 L-B -

5 R-Y - 15 W-B -
6 R-Y - 16 - -
7 - - 17 P -
8 - - 18 - -
9 R - 19 - -
10 P-L - 20 B -
C111 to Roof Wire Harness C112 to Front Door Wire Harness RH

1 L-R - 1 G-Y -
2 - - 2 W-R -
3 R - 3 L-Y -
4 LG - 4 L-Y -
5 O - 5 G-R -
6 - - 6 R-L -
7 W-R - 7 R -
8 - - 8 G -
C113 to Front Door Wire Harness RH C114 to Front Door Wire Harness RH
1 LG - 1 W-B -
2 L - 2 LG -
3 P-B - 3 P -
4 LG-B - 4 - -
5 LG-R - 5 - -
6 Y -
71
71
C115 to Front Body Wire Harness

(with 4G63/4G64 Engine)
1 R-Y - 11 - -
2 - - 12 - -
3 - - 13 L -
4 - - 14 R -
5 - - 15 W-B -
6 W-G - 16 G -
7 W-B - 17 - -
8 R - 18 G-R -
9 R - 19 R-L -
10 G - 20 Y-R -
C116 to Front Body Wire Harness (with 4G63/4G64 Engine)

1 R - 13 B-W -
2 W - 14 R-Y -
3 B - 15 - -
4 Y - 16 G-R -
5 Y-G - 17 W-R -
6 R-Y - 18 R -
7 B-Y - 19 P -
8 R-Y - 20 LG -
C116 to Front Body Wire Harness (with 4G63/4G64 Engine)

9 G-Y - 21 R-W -
10 G-B - 22 - -
11 BR - 23 G-W -
12 L - 24 R-W -
C118 to Combined Display Wire Harness

1 GR - 8 W-L -
2 - - 9 Y -
3 G - 10 - -
4 R - 11 - -
5 W-B - 12 - -
6 W-B - 13 - -
7 BR-W - 14 - -
C120 to Front Door Wire Harness LH

1 W-B - 5 GR -
2 R - 6 P -
3 G - 7 LG -
4 L-R - 8 G-B -
71
71
C121 to Front Body Wire Harness (with BJ493ZQ3 Engine)

1 Y-G - 18 - -
2 R - 19 B-W -
3 Y-G - 20 R-Y -
4 W - 21 - -
5 B - 22 G-R -
6 Y - 23 W -
7 G-B - 24 Y -
8 W-R - 25 W-B -
9 W-B - 26 B -
10 R-Y - 27 R-W -
11 - - 28 - -
12 - - 29 - -
13 R-Y - 30 R-W -
14 G-Y - 31 L-W -
15 R - 32 G-Y -
16 G-W - 33 GR -
17 R - 34 - -
C122 to Front Body Wire Harness (with BJ493ZQ3 Engine)

1 V-W - 18 - -
2 V-O - 19 W-R -
3 - - 20 Y-W -
4 - - 21 B-G -
5 R-B - 22 L -
6 G - 23 BR -
7 R - 24 B-Y -
8 R-Y - 25 W-B -
9 W-B - 26 R-Y -
10 Y-R - 27 L-G -
11 R-L - 28 - -
12 G-R - 29 L-B -
13 G - 30 L-Y -
14 R - 31 - -
15 L - 32 Y-L -
16 R-L - 33 L-B -
17 R-B - 34 R -
C123 to Engine Control Wire Harness (with BJ493ZQ3 Engine)

1 O - 5 B-O -
2 W-R - 6 W -
3 Y-B - 7 - -
4 L-O - 8 L -
71
C401 Combined Display 71

1 R Temperaturel 8 - -
2 - - 9 W-B Ground
3 - - 10 W-B Ground
4 BR-W Vehicle Speed 11 G Interior Lighting
5 Y Signal Input 12 - -
6 W-L Calculagraph 13 GR Power Supply
7 - -
C501 to Instrument Panel Wire Harness

1 GR - 8 W-L -
2 - - 9 Y -
3 G - 10 - -
4 R - 11 - -
5 W-B - 12 - -
6 W-B - 13 - -
7 BR-W - 14 - -
C601 Data Link Connector

1 - - 9 - -
2 - - 10 - -

3 - - 11 - -
4 BR - 12 - -
5 W-B - 13 - -
6 G-O - 14 G-B -
7 L-B 15 - -
8 - - 16 W -

1 G-B - 5 W-B -
2 G-O - 6 R-L -
3 W - 7 P-B -
4 BR - 8 L-B -
D - REAR FOG LAMP WIRE HARNESS
71
71
D001 Reverse Radar Sensor LH D004 Reverse Radar Sensor RH

1 B Ground 1 B Ground
2 R-G Input 2 R-W Input
D002 Rear Fog Lamp LH D005 Rear Fog Lamp RH

1 R-Y Input 1 R-Y Input
D003 Reverse Radar Sensor Mid D101 to Rear Body Wire Harness LH
1 B Ground 1 B -
2 R-B Input 2 W-B -
3 R-Y -
4 R-G -
5 R-B -
6 R-W -
E001 Coolant Temperature Indicator E005 Fuel Injector 4

1 Y-G Input 1 R Main Relay
2 GR-B Fuel Injector 4
E002 Fuel Injector 1 E006 Knock Sensor

1 R Main Relay 1 P-L Signal
2 GR Fuel Injector 1 2 BR Ground
E003 Fuel Injector 2 E007 Throttle Position Sensor

1 R Main Relay 1 BR Ground
2 GR-R Fuel Injector 2 2 G-B 5V Power Supply
3 R-G TP Sensor
E004 Fuel Injector 3 E008 Canister Solenoid Valve

1 R Main Relay 1 G-O anister Solenoid Valve
2 GR-W Fuel Injector 3 2 R Main Relay

71
E009 Idle Air Control E013 Crankshaft Position Sensor
71
1 B-Y Idle Air Control Coil A 1 W-B Ground
2 B-G Idle Air Control Coil B 2 L Low Voltage
3 G-R Idle Air Control Coil C 3 G High Voltage
4 G-L Idle Air Control Coil D
E010 MAP/IAT Sensor E015 Downstream Oxygen Sensor

1 BR-B Ground r 1 W Low Voltage
2 R-B Temperature 2 L-W High Voltage
3 R 5V Power Supply 3 V Heat Control
4 L-B Pressure 4 R Power Supply
E011 Back-up Lamp Switch E016 Odometer Sensor

1 B Back-up Lamp Switch 1 G-R Ignition
2 G-R Ignition 2 W-B Ground
3 W-G Vehicle Speed
E012 Starter Motor E018 Generator

1 B - B R Power Output
E017 Upstream Oxygen Sensor E020 Ignition Coil

1 W Low Voltage 1 W-L Ignition Control (2,3)
2 P-B High Voltage 2 GR Ignition
3 P Heat Control 3 G-W Ignition Control (1,4)
4 R Power Supply
E019 Generator E021 Engine Coolant Temperature Sensor

1 P-L Ignition 1 Y-B Signa
2 R-W Terminal S 2 BR Ground
E022 A/C Clutch Field Coil E024 Engine Oil Pressure Switch
1 B-O Input 1 L Input
E023 Engine Control Module

1 G Ignition 38 L-W Downstream O2S (Hi )
2 - - 39 L-R ACI

3 W-G Vehicle Speed 40 - - 71
4 R Ground - Sensor 41 - -
71
5 BR Ground - Sensor 42 L-B Signal - MAP Sensor
6 R Ground - O2 Sensor 43 Y-B Signal - ECT Sensor
7 - - 44 - -
8 - - 45 Y-W Signal -CKP Sensor
9 L Signal - A/C Pressure 46 Y-L ACT
10 - - 47 Y-R Fuel Pump Control
11 Y Diagnostic K Line 48 - -
12 G CKP Sensor(Hi) 49 - -
13 - - 50 W-Y Fan Control (Hi)
14 - - 51 - -
15 - - 52 W-L Ignition Control (2,3)
16 - - 53 B-G Idle Air Control Coil B
17 R-Y Power Supply 54 B-Y Idle Air Control Coil A
18 R-Y Power Supply 55 GR Fuel Injector 1
19 - - 56 GR-W Fuel Injector 3
20 G-B 5V Power Supply 57 - -
21 BR-B 5V Power Supply 58 LG Main Relay
22 - - 59 - -
23 R-B Fuel Level 60 - -
24 R-G TP Sensor 61 P Heat - Upstream O2S
25 - - 62 P-B Upstream O2S (Hi )
26 - - 63 G-O Canister Valve
27 R-B IAT Sensor 64 V Downstream O2S
28 L CKP (Low Voltage) 65 - -
29 O SVS Warning Light 66 - -
30 R-W Diagnosis 67 V-W Fan Control (Low)
31 R-L Malfunction Indicator 68 - -
32 G-W Ignition Control (1,4) 69 P-L Knock Sensor
33 G-R Idle Air Control Coil C 70 GR-R Fuel Injector 2
34 G-L Idle Air Control Coil D 71 GR-B Fuel Injector 4


35 L-R Accelerator 72 - -
36 - - 73 W-B Ground
37 - -
E025 Fuel Injector 1 E027 Fuel Injector 3

1 W Fuel Injector 1 (Hi) 1 W Fuel Injector 3 (Hi)
2 B Fuel Injector 1 (Lo) 2 L Fuel Injector 3 (Lo)
E026 Fuel Injector 2 E028 Fuel Injector 4

1 W Fuel Injector 2 (Hi) 1 W Fuel Injector 4 (Hi)
2 R Fuel Injector 2 (Lo) 2 G Fuel Injector 4 (Lo)
E029 Preheat Plug E031 Preheat Plug

1 R Preheat 1 R-L Preheat
E030 Preheat Plug E032 Preheat Plug

1 L Preheat 1 GR Preheat
71
E036 High Pressure Pump
Solenoid Control Valve 71

E033 Preheat Interface
1 W-L High Pressure Pump
2 R-L High Pressure Pump
1 R Preheat
2 L Preheat
3 R-L Preheat
4 GR Preheat
5 - - E037 Cooling Fan Temperature Sensor

6 - - Pin Color Function Qualifier
1 R-Y Temperature
2 W-Y Temperature
E034 Camshaft Position Sensor

E038 Engine Coolant Temperature Sensor
1 Y 5V Power Supply
2 Y-R Signal
1 BR-W Signal
3 V Ground
2 B Ground
E039 Engine Oil Pressure Switch

E035 Mass Air Flow Sensor
1 GR Signal
1 W-L IAT Sensor
2 GR MAF Sensor
3 G-R Ground E040 Coolant Temperature Indicator

4 L-W Power Supply
1 Y-B Output
E041 Common Rail Pressure Sensor E042 Crankshaft Position Sensor

1 W Ground r 1 L Signal
2 Y-B Signal 2 GR Signal
3 G 5V Power Supply

A1 W Fuel Injector 3 (Hi) A31 R Fuel Injector 2 (Lo)
A2 W Fuel Injector 2 (Hi) A32 - -
A3 - - A33 G Fuel Injector 4 (Lo)
A4 - - A34 - -
A5 - - A35 - -
A6 - - A36 - -
A7 B Shield A37 GR Signal - MAF Sensor
A8 W Sensor Ground A38 - -
A9 - - A39 - -
A10 - - A40 - -
A11 Y 5V Power Supply A41 B Sensor Ground
A12 L Signal - CKP Sensor A42 W-L Signal - IAT Sensor
Common Rail
A13 - - A43 Y-B
Pressure Sensor
A14 - - A44 G-R Sensor Ground
A15 - - A45 - -
A16 W Fuel Injector 1 (Hig) A46 L Fuel Injector 3 (Lo)
A17 W Fuel Injector 4 (Hi) A47 B Fuel Injector 1 (Lo)
A18 - - A48 - -

High Pressure Pump High Pressure Pump 71
A19 R-L A49 W-L
Solenoid Control Valve Solenoid Control Valve
Camshaft Position 71
A20 V Sensor Ground A50 Y-R
Sensor
A21 - - A51 - -
A22 - - A52 - -
A23 - - A53 - -
A24 - - A54 - -
A25 - - A55 - -
A26 - - A56 - -
A27 GR CKP Sensor A57 - -
A28 G 5V Power Supply A58 BR-W ECTSensor
A29 - - A59 - -
A30 - - A60 W EGR Valve
E102 to Instrument Panel Wire Harness

1 B - 11 Y-L -
2 R - 12 W-G -
3 LG - 13 - -
4 - - 14 W-Y -
5 - - 15 V-W -
6 G-R - 16 - -
7 Y-G - 17 B -
8 L - 18 L -
9 R-W - 19 G -
10 - - 20 - -

1 R-Y - 11 Y-W -
2 L-R - 12 Y-R -
3 - - 13 BG -
4 G - 14 L-R -
5 R-L - 15 O -
6 - - 16 R-W -
7 Y - 17 B-O -
8 - - 18 - -
9 P-L - 19 - -
10 G-B - 20 R-B -
E302 Generator
E106 to Instrument Panel Wire Harness Pin Color Function Qualifier
Pin Color Function Qualifier 1 Y-R Ignition
1 R-Y -
2 - -
3 Y-B -
4 W-Y -
5 L-W -
6 W -
E303 Generator
7 - - Pin Color Function Qualifier
8 GR - 1 R Power Output
71
71
E304 Generator E400 to Engine Room Wire Harness
Charging Warning 1 Y-R -
1 P-L
Light
2 P-L -
2 R Terminal S
3 B-O -
4 B -
E305 A/C Clutch Field Coil E401 to Battery Wire Harness

1 B-O - 1 B -
F - ROOF WIRE HARNESS
F001 Front Indoor Lamp F003 Sliding Roof Control Motor

1 R Power Supply 1 LG Control Motor (B)
2 W-R Output 2 W-B Ground
3 Y Limit Switch (Open)
4 P Control Motor (A)
5 W-B Ground
6 L Limit Switch (Close)
F004 Rear Indoor Lamp

1 W-B Ground
2 R-Y Output
F005 Sliding Roof Control Switch
3 R Power Supply Pin Color Function Qualifier

1 R-Y Control Switch (OFF)
2 W-B Ground
3 B-L Control Switch (ON)
F007 Sliding Roof Control Module F006 Antenna Amplifier

1 R 12V Power Supply 1 - -
2 R-Y Control Switch (OFF) 2 BR Signal Output
3 B-L Control Switch (ON) 3 B-L Signal Output
4 W-B Ground 4 V Defrost Relay
5 P Control Motor (A)
6 L Position (Full Closed)
7 Y Position (Full Open)
8 LG Control Motor (B)

71
71
F101 to Instrument Panel Wire Harness

1 R - 11 G -
2 W-R - 12 G-W -
3 GR - 13 G-W -
4 L - 14 Y -
5 R-Y - 15 W-B -
6 R-Y - 16 - -
7 - - 17 R -
8 - - 18 - -
9 R - 19 - -
10 P - 20 V -
F102 to Instrument Panel Wire Harness F103 to Rear Hatch Wire Harness #1
1 L-B - 1 G -
2 - - 2 R -
3 R - 3 R-Y -
4 W-R - 4 B-L -
5 O - 5 G-W -
6 - - 6 G-W -
7 R-W -
8 - -
F104 to Rear Hatch Wire Harness #1 F105 to Rear Evaporator Wire Harness
1 W-B -
1 L-B -
2 - -
2 - -
3 L -
3 - -
4 P -
4 R -
5 Y -
5 R -
6 - -
6 R-W -
7 W-R -
8 O -
9 - -
10 W-B -
F304 Rear Evaporator Resistor
11 - -
1 R-B High Speed (HI)
2 L-W High Speed (Mid)
3 B-W Ground
F301 Rear Intake Sensor

1 W-G Ground
F305 Rear Evaporator Motor LH
2 W-Y Signal
1 R-B Signal Input
2 W-L Signal Output
F302 Rear Temperature Control Switch

F306 Rear Evaporator Motor RH 1 Y-W Control Switch
Pin Color Function Qualifier 2 W-Y Rear Intake Sensor
1 R-B Input
2 R Output
71
F307 Rear Evaporator Control Panel
Illumination LH 71

F309 Rear Evaporator Blower Switch
1 L-W Power Supply
2 B-W Ground Pin Color Function Qualifier

1 L-W Mid Speed (M)
2 - -
3 - -
F308 Rear Evaporator Control Panel 4 G-Y Inpu

Illumination RH 5 - -
Pin Color Function Qualifier 6 R-B High Speed (H)
1 L-W Power Supply 7 - -
2 B-W Ground 8 B-W Ground
F401 to Roof Wire Harness

1 L-B - 7 Y-W -
2 - - 8 W-Y -
3 - - 9 - -
4 G-Y - 10 B-W -
5 R - 11 - -
6 W-G -
G - REAR BODY WIRE HARNESS RH
G001 Sliding Door Ajar Switch RH G003 Double Diode

1 R-W Ajar Switch RH 1 R-Y -
2 R-W -
3 R-L -
G002 Rear Speaker RH

1 R Rear Speaker RH - G007 Sliding Door Step Lamp RH
2 W Rear Speaker RH + Pin Color Function Qualifier
1 R Power Supply
2 R-Y Signal Input
G004 Cargo Lamp

1 R Power Supply
2 R-B Cargo Lamp
G101 to Front Body Wire Harness

1 R-B -
2 BR-G -
G005 Rear Combination Lamp RH
3 - -
Pin Color Function Qualifier 4 R-W -
1 G-R Tail Lamp 5 B-G -
2 G-W Stop Lamp 6 R-L -
3 G-Y Turn Signal Lamp 7 - -
4 W-B Ground 8 - -
5 B-R Back-up Lamp
6 - - Stopper
71
71

1 B - 13 G-R -
2 Y - 14 Y-B -
3 W - 15 Y-G -
4 R - 16 G-W -
5 R-Y - 17 L -
6 G-B - 18 BR -
7 G-Y - 19 G-R -
8 B-R - 20 R-Y -
9 W-R - 21 - -
10 R - 22 W-G -
11 R - 23 R-B -
12 W-R - 24 R-W -
G103 to Chassis Wire Harness RH

1 W-R - 11 G-R -
2 R - 12 W-G -
3 Y-G - 13 - -
4 - - 14 R-L -
5 BR-G - 15 B -
6 B-G - 16 W-B -

7 - - 17 - -
8 - - 18 - -
9 - - 19 - -
10 Y-B - 20 W-R -
G104 to Rear Body Wire Harness LH

w/ Rear
1 G-R - 11 L -
Heater
w/o Rear
2 G-B - 12 - -
Heater
w/o Rear w/ Rear

3 R - 12 R -
Heater Heater
w/ Rear
3 Y 13 - -
Heater
4 B - 14 R-Y -
w/o Rear
5 B-R - 15 - -
Heater
w/ Rear
6 G-W - 15 R-L -
Heater
w/o Rear w/o Rear

7 - - 16 - -
Heater Heater
w/ Rear w/ Rear
7 G 16 Y-R -
Heater Heater
w/o Rear
8 - - 17 B -
Heater
w/ Rear
9 - - 17 BR -
Heater
w/o Rear
10 R-L - 18 L -
Heater
w/ Rear
10 - - 19 R-B -
Heater
w/o Rear
11 - - 20 R-W -
Heater
71
71

1 BR-G - 8 - -
2 G - 9 - -
3 - - 10 R-B -
4 L - 11 R-W -
5 R - 12 R-L -
6 B-G - 13 Y-R -
7 R-L -
H - REAR BODY WIRE HARNESS LH
H001 Sliding Door Ajar Switch LH H002 Rear Speaker LH

1 R-L Ajar Switch LH 1 B Rear Speaker LH +
2 Y Rear Speaker LH -
H005 Rear Combination Lamp LH H006 Rear Heater Blower Switch

1 G-R Tail Lamp 1 W-B Ground
2 G-W Stop Lamp 2 - -
3 G-B Turn Signal Lamp 3 L-B Mid Speed (M)
4 W-B Ground 4 L-Y Low Speed (LO)
5 B-R Back-up Lamp 5 - -
6 - - 6 R-L High Mid Speed (HI)
H009 Rear Heater Control Panel

Illumination H008 Rear Heater Blower Motor
1 W-B Ground 1 L Power Supply
2 G Input - Switch 2 R-L High Speed (HI)
3 W-B Ground 3 L-Y Mid Speed (M)
4 L-B Low High Speed (LO)

71
71
H007 Rear Heater Switch (Rear Control) H102 to Rear Fog Lamp Wire Harness
1 W-B Ground 1 BR -
2 Y-R Power Supply 2 W-B -
3 R Rear Heater Switch 3 R-Y -
4 W-B Ground 4 R-G -
5 G Input - Switch 5 R-B -
6 R-L Power Supply 6 R-W -
H101 to Rear Body Wire Harness RH

w/ Rear
1 G-R - 12 R -
Heater
2 G-B - 13 - -
3 Y - 14 R-Y -
w/o Rear
4 B - 15 - -
Heater
w/ Rear
5 B-R - 15 R-L -
Heater
w/o Rear
6 G-W - 16 - -
Heater
w/o Rear w/ Rear

7 - - 16 Y-R -
Heater Heater
w/ Rear w/o Rear

7 G - 17 BR -
Heater Heater
w/ Rear
8 - - 17 B -
Heater
H101 to Rear Body Wire Harness RH

w/o Rear
9 - - 18 R-G -
Heater
w/o Rear w/ Rear

10 R-L - 18 P -
Heater Heater
w/ Rear w/o Rear

10 - - 19 R-B -
Heater Heater
w/o Rear w/ Rear

11 - - 19 L -
Heater Heater
w/ Rear w/o Rear

11 L - 20 R-W -
Heater Heater
w/o Rear w/ Rear

12 - - 20 L-G -
Heater Heater
I - REAR HATCH WIRE HARNESS #1
71
71
I001 High-mounted Stop Lamp

1 W-B Ground 2 G-W Signal Input
I101 to Roof Wire Harness I102 to Roof Wire Harness

1 W-B - 1 G -
2 - - 2 R -
3 L - 3 R-Y -
4 P - 4 B-L -
5 Y - 5 G-W -
6 - - 6 G-W -
I103 to Rear Hatch Wire Harness #2

1 R - 7 - -
2 G - 8 B-L -
3 - - 9 P -
4 W-B - 10 Y -
5 G-W - 11 L -
6 R-Y -
J - REAR HATCH WIRE HARNESS #2
J001 Rear Window Defrost Grid J003 License Lamp

1 W-B Ground 1 G Power Supply
2 W-B Ground
J002 Rear Wiper Motor J004 Rear Hatch Lock Actuator

1 P Signal Input 1 G-W Actuator (Close)
2 L Ignition 2 R Actuator (Open)
3 W-B Ground
4 Y Signal Input
J005 Rear Hatch Ajar Switch

J006 Rear Window Defrost Grid Pin Color Function Qualifier
Pin Color Function Qualifier 1 R-B Door Ajar Switch
1 B-L Signal Input 2 W-B Ground
J101 to Rear Hatch Wire Harness #1

1 R - 7 - -
2 G - 8 B-L -
3 - - 9 P -
4 W-B - 10 Y -
5 G-W - 11 L -
6 R-B -
K - CHASSIS WIRE HARNESS RH
71
71
K001 Rear Evaporator Solenoid K004 Back-up Lamp Switch

1 Y-G - 1 B Output
2 R-Y - 2 G-R Input
K002 Front Door Ajar Switch RH K005 Odometer Sensor

Pin Color Function Qualifier Qualifie
Pin Color Function
r
1 W-R Ajar Switch RH
1 G-R Input
2 W-B Ground
3 W-G Output
K003 Sliding Door Lock Actuator RH K006 Vacuum Alarm
1 R Actuator RH (Open) 1 R-L Output
2 - -
3 G Actuator RH (Close)
4 - -
K101 to Rear Body Wire Harness RH

1 G - 12 - - 4G Series
2 R - 12 W-G - BJ Series
3 Y-G - 13 - -
4 - - 14 - - 4G Series
5 - - 4G Series 14 R-L - BJ Series
5 BR-G - BJ Series 15 - - 4G Series
6 - - 4G Series 15 B - BJ Series
6 B-G - BJ Series 16 - - 4G Series
7 - - 16 W-B - BJ Series
8 - - 17 - -
9 - - 18 - -
10 R-Y - 19 - -
11 - - 4G Series 20 W-R -
11 G-R - BJ Series
L - CHASSIS WIRE HARNESS LH
71
71
L001 Front Door Ajar Switch LH L005 Fuel Level Sensor
1 W-G Door Ajar Switch LH 1 V Output
2 BR Ground
L002 Sliding Door Lock Actuator LH L006 Rear Wheel Speed Sensor RH
1 R Actuator (Open) 1 LG Right Rear -
2 - - 2 P Right Rear +
3 G Actuator (Close)
4 - -
L003 Sliding Door Step Lamp LH L007 Rear Wheel Speed Sensor LH
1 R Power Supply 1 L Left Rear -
2 R-B Door Ajar Switch 2 Y Left Rear +
L004 Fuel Pump L008 Water Valve

1 W-B Ground 1 GR-B -
2 W-R Power Supply 2 Y-R -

L101 to Instrument Panel Wire Harness

w/ Rear
1 - - 10 - -
Heater
w/o Rear
2 - - 11 BR -
Heater
w/ Rear
2 GR-B - 12 V -
Heater
w/o Rear
3 - - 13 - -
Heater
w/ Rear
3 Y-R - 14 - -
Heater
4 W-G - 15 - -
5 W-B - 16 - -
6 W-R - 17 P -
7 Y - 18 LG -
w/o Rear
8 L - 19 G -
Heater
w/o Rear w/ Rear

9 R-B - 19 - -
Heater Heater
w/ Rear w/o Rear

9 - - 20 R -
Heater Heater
w/o Rear w/ Rear

10 R - 20 - -
Heater Heater
M - FRONT DOOR WIRE HARNESS RH
71
71
M001 Front Door Lock Actuator RH M002 Front Power Window Switch RH
1 - - 1 LG Power Supply
2 G Actuator (Close) 2 - -
3 - - 3 P Switch RH (Up)
4 R Actuator (Open) 4 L-Y Switch RH (Down)
5 - -
M003 Front Speaker RH M004 Front Power Window Motor RH
1 LG Front Speaker RH + 1 R-L Motor RH (Down)
2 L Front Speaker RH - 2 G-R Motor RH (Up)
M005 Outside Mirror RH

1 Y Unfold 6 W-B Ground
2 LG-B Right 7 G-Y Turn Signal Lamp
3 P-B Left/Down 8 L-Y Heating
4 LG-R UP 9 W-R Ignition
5 - - 10 L Fold
M101 to Instrument Panel Wire Harness M103 to Instrument Panel Wire Harness
1 G-Y - 1 LG -
2 W-R - 2 L -
3 L-Y - 3 P-B -
4 L-Y - 4 LG-B -
5 G-R - 5 LG-R -
6 R-L - 6 Y -
7 R -
8 G -
M102 to Instrument Panel Wire Harness

1 W-B -
2 LG -
3 P -
4 - -
5 - -
N - FRONT DOOR WIRE HARNESS LH
71
71
N001 Outside Mirror Remote Control

Switch N003 Outside Mirror LH
1 GR-R Signal Output - Switch 1 Y Unfold
2 LG-R Signal Output - Switch 2 GR-L Right
3 P-B Signal Output - Switch 3 P-B Left/Down
4 W-B Ground 4 GR-R Up
5 LG-B Signal Output - Switch 5 - -
6 GR Ignition 6 W-B Ground
7 GR-L Signal Output - Switch 7 G-B Turn Signal Lamp
8 Y Signal Output - Switch 8 L-Y Heating
9 W-R Ignition
10 L Fold
N002 Main Power Window and Door Lock/unlock Switch

1 LG Output 7 - -
2 P Switch RH (Up) 8 - -
3 L-Y Switch RH (Down) 9 L-B Illumination
4 L Output 10 - -
5 L-B Output 11 - -
6 L-Y Power Supply 12 W-B Ground

N004 Front Power Window Motor LH N005 Front Speaker LH

1 G Motor (Down) 1 P Front Speaker LH +
2 R Motor (Up) 2 V Front Speaker LH -
N006 Front Door Lock Actuator LH N102 to Instrument Panel Wire Harness
1 R Actuator (Open) 1 G-B -
2 W-B Ground 2 W-R -
3 G Actuator (Close) 3 L-Y -
4 L-R Switch (Open) 4 L-Y -
5 - - 5 L -
6 L-O Switch (Close) 6 L-B -
7 R -
8 G -
N103 to Instrument Panel Wire Harness N104 to Instrument Panel Wire Harness
1 W-B - 1 L-O -
2 R - 2 P-B -
3 G - 3 P -
4 L-R - 4 V -
5 GR - 5 L-Y -
6 P - 6 LG-B -
7 LG - 7 LG-R -
8 L-B - 8 Y -
Q - FRONT BODY WIRE HARNESS
71
71
Q001 Rear Heater Switch (Rear Control) Q004 Seat Belt Buckle Switch
1 W-B Ground 1 B-W Output
2 Y-R Power Supply 2 W-B Ground
3 R Power Supply
4 W-B Ground
5 G Illumination
6 R-L Power Supply

Q005 In-vehicle Temperature Sensor
1 R Output
2 W-B Ground
Q002 Rear Heater Control Panel
Illumination
1 W-B Ground
Q006 Parking Brake Switch
2 R Illumination
1 R-W Parking Brake Switch
Q003 Rear Heater Blower Motor Q007 Rear Heater Blower Switch
1 L Power Supply 1 W-B Ground
2 R-L High Speed (HI) 2 - -
3 L-Y Mid Speed (M) 3 L-B Mid Speed (M)
4 L-B Low Speed (LO) 4 L-Y Low Speed (LO)
5 - -
6 R-L High Speed (HI)

Q010 Engine Control Module (with BJ493ZQ3 Engine)

k1 R-B Power Supply k48 Y-W CKP Sensor
k2 W-B Ground k49 - -
k3 R Power Supply k50 - -
k5 R Power Supply k52 Y-G Preheat
k7 - - k54 W-R ACI
k8 V-O Ground - APP Sensor k55 - -
k9 V-W Signal - APP Sensor k56 - -
k10 - - k57 - -
k11 - - k58 Y Clutch Switch
k12 - - k59 - -
k13 - - k60 - -
k14 - - k61 - -
k15 - - k62 - -
k16 - - k63 - -
k17 B-Y Stop Lamp Switch k64 - -
k18 - - k65 - -
k19 - - k66 - -
k20 - - k67 - -
k21 - - k68 W ACT
k22 - - k69 R-W Output
k23 - - k70 - -
k24 - - k71 - -
k25 L-B Diagnosis k72 L-G Main Relay
k26 - - k73 - -
k27 - - k74 - -
Q010 Engine Control Module (with BJ493ZQ3 Engine)

k28 B-G Signal Input - Ignition k75 B Signal - Vehicle Speed 71
k29 - - k76 -
71
k30 BR Ground - APP Sensor k77 -
k31 L Signal - APP Sensor k78 -
k32 - - k79 -
k33 - - k80 GR Stop Lamp Switch
k34 - - k81 - -
k35 - - k82 - -
k36 - - k83 - -
k37 - - k84 - -
k38 - - k85 - -
k39 - - k86 - -
k40 Y-L Oil Water Separator k87 - -
k41 - - k88 - -
k42 R-W Input k89 - -
k43 - - k90 - -
k44 - - k91 R-Y Malfunction Indicator
k45 L-Y Power - APP Sensor k92 L-W Preheat Indicator Light
k46 L-B Power - APP Sensor k93 G-Y Output - Preheat
k47 - - k94 - -
Q101 to Rear Body Wire Harness RH

1 B - 13 G-R -
2 Y - 14 R-Y -
3 R - 15 Y-G -
4 W - 16 G-W -

5 R-Y - 17 L -
6 G-B - 18 B -
7 G-Y - 19 G-R -
8 B-R - 20 R-Y -
9 G - 21 - -
10 R - 22 W-G -
11 R - 23 P -
12 W-R - 24 LG -

1 R-Y - 5 B-G -
2 BR-G - 6 R-L -
3 - - 7 - -
4 R-W - 8 - -
Q103 to Instrument Panel Wire Harness (with 4G63/4G64 Engine)

1 R-Y - 11 - -
2 - - 12 - -
3 B-G - 13 L -
4 BR-G - 14 R -
5 R-L - 15 W-B -

6 W-G - 16 G - 71
7 W-B - 17 - -
71
8 R - 18 G-R -
9 R - 19 R-L -
10 G - 20 Y-R -

1 R - 13 B-W -
2 W - 14 R-Y -
3 B - 15 - -
4 Y - 16 G-R -
5 Y-G - 17 W-R -
6 R-Y - 18 R -
7 B-Y - 19 P -
8 R-Y - 20 LG -
9 G-Y - 21 R-W -
10 G-B - 22 - -
11 B - 23 G-W -
12 L - 24 R-W -

1 - - 8 - -
2 G - 9 - -
3 - - 10 R-Y -
4 L - 11 R-W -
5 R - 12 R-L -
6 - - 13 Y-R -
7 R-L -
Q106 to Instrument Panel Wire Harness (with BJ493ZQ3 Engine)

1 Y-G - 18 P -
2 W - 19 B-W -
3 Y-G - 20 R-Y -
4 R - 21 - -
5 B - 22 G-R -
6 Y - 23 W-R -
7 G-B - 24 Y -
8 W-R - 25 W-B -
9 W-B - 26 B -
10 R-Y - 27 R-W -
11 B - 28 L -
12 B-R - 29 LG -

13 R-Y - 30 R-W - 71
14 G-Y - 31 L-W -
71
15 R - 32 G-Y -
16 G-W - 33 GR -
17 R - 34 - -

1 V-W - 18 - -
2 V-O - 19 W -
3 R - 20 Y-W -
4 W-B - 21 B-G -
5 W-G - 22 L -
6 G - 23 BR -
7 R - 24 B-Y -
8 R-Y - 25 W-B -
9 W-B - 26 R-Y -
10 Y-R - 27 L-G -
11 R-L - 28 - -
12 G-R - 29 L-B -
13 G - 30 L-Y -
14 R - 31 - -
15 L - 32 Y-L -
16 R-L - 33 L-B -
17 R-B - 34 R -
71-242 WIRING - WIRE HARNESS & CONNECTOR LOCATION VIEWS
WIRE HARNESS & CONNECTOR LOCATION VIEWS

A - ENGINE ROOM WIRE HARNESS
B - FAN WIRE HARNESS
Engine Room Wire Harness - Connector

A002 Front Wheel Speed Sensor LH A011 Front Fog Lamp RH
A003 Brake Fluid Level Sensor A012 Dual Function Pressure Switch
A004 Front Fog Lamp LH A013 Front Combination Lamp RH
A005 Engine Coolant Fluid Level Sensor A014 Preheat Controller
Front Combination Lamp LH A015 Preheat Controller

A006
(Turn Signal Lamp)
A016 Oil Water Separator
A007 Front Combination Lamp LH
A017 Heated Switch
Front Combination Lamp RH
A008 A018 Heater
(Turn Signal Lamp)
A009 Horn LH A301 Engine Room Junction Box
A010 Horn RH
WIRING - WIRE HARNESS & CONNECTOR LOCATION VIEWS 71-243
Engine Room Wire Harness - Inline

A101 to Instrument Panel Wire Harness A104 to Instrument Panel Wire Harness
A102 to Instrument Panel Wire Harness to Engine Room Sub-harness

A105 71
A103 to Fan Wire Harness
71
Engine Room Wire Harness - Ground Points

e
A201 Left Side of the Engine Room A203 Right Side of the Engine Room
A202 Left Side of the Engine Room A204 Right Side of the Engine Room
Fan Wire Harness - Connector

B001 Main Fan Motor B301 Fan Junction Box
B002 Secondary Fan Motor
Fan Wire Harness - Inline
B101 to Engine Room Wire Harness

C - INSTRUMENT PANEL WIRE HARNESS (INCLUDING DIAGNOSIS

WIRE HARNESS & COMBINED DISPLAY WIRE HARNESS)
Instrument Panel Wire Harness - Connector

C001 Rear Fog Lamp Switch C031 Audio
C002 Multi-function Controller (3-in-1) C032 Audio

71
C003 Multi-function Controller (3-in-1) C033 Ignition Switch
71
C004 Stop Lamp Switch (with 4G63/4G64 Engine) C034 Hazard Switch
C005 A/C Cut Relay C035 Electronic Clock
C006 Front Blower Motor Resistor C036 Front Washer Pump
C007 Front Intake Sensor C037 Rear Washer Pump
C008 A/C Amplifier C038 ABS Module
C009 Rear Evaporator Motor Relay Combination Switch

C039
(Wiper and Washer Control)
C010 A/C Clutch Relay
C040 Combination Switch (Light Control)）
C011 Capacitance
C012 Diode
C042 Ignition Key Position Remind Controller
C014 Front Wiper Motor
C043 Multi-function Door Lock Controller (4-in-1)
C015 Front Wheel Speed Sensor RH
C044 Double Diode
C016 Accelerator Sensor
C017 Front A/C Controller (Auto)
C046 Fresh/Recirculation Door Actuator
C018 12V Power Point Socket
C047 Front Blower Motor
C019 Outside Mirror Defrost Switch
Accelerator Pedal Positon Sensor
C020 Rear Heater Switch (Front Control) C050
C021 Power Point Socket (Cigarette Lighter) C051 Stop Lamp Switch (with BJ493ZQ3 Engine)
C022 Rear Window Defrost Switch C052 Clutch Switch (with BJ493ZQ3 Engine)
C023 Rear A/C Switch (Front Control) C053 EGR Valve (with BJ493ZQ3 Engine)
C024 Blower Switch Cooling Fan Control Module
C054
C025 Blend Door Actuator
C060 Front A/C Controller (Manual)
C026 Mode Door Actuator
C301 Body Junction Box
C401 Combined Display
C028 Ignition Keyhole Illumination
C029 Ignition Position Switch
C030 Clock Spring

Instrument Panel Wire Harness - Inline

C101 to Chassis Wire Harness LH C114 to Front Door Wire Harness RH
C102 to Engine Control Wire Harness to Front Body Wire Harness

C115 71
to Front Body Wire Harness 71
C116
C104 to Front Door Wire Harness LH (with 4G63/4G64 Engine)
C105 to Front Door Wire Harness LH C118 to Combined Display Wire Harness
C106 to Engine Room Wire Harness C120 to Front Door Wire Harness LH
C107 to Engine Room Wire Harness to Front Body Wire Harness

C121
to Front Body Wire Harness
C109 to Diagnosis Wire Harness C122
C110 to Roof Wire Harness to Engine Control Wire Harness
C123
C112 to Front Door Wire Harness RH
C113 to Front Door Wire Harness RH
Instrument Panel Wire Harness - Ground Points

C212 Left Side of the Instrument Panel C244 Left Side of the Instrument Panel
C213 Left Side of the Instrument Panel C245 Left Side of the Washer Pump
D - REAR FOG LAMP WIRE HARNESS

Rear Fog Lamp Wire Harness - Connector

D001 Reverse Radar Sensor LH D004 Reverse Radar Sensor RH
D002 Rear Fog Lamp LH D005 Rear Fog Lamp RH
D003 Reverse Radar Sensor Mid
Rear Fog Lamp Wire Harness - Inline
D101 to Rear Body Wire Harness LH
Rear Hatch Wire Harness #1 - Connector
I001 High-mounted Stop Lamp

Rear Hatch Wire Harness #1 - Inline

I101 to Roof Wire Harness I103 to Rear Hatch Wire Harness #2
I102 to Roof Wire Harness 71
Rear Hatch Wire Harness #2 - Connector 71
J001 Rear Window Defrost Grid J004 Rear Hatch Lock Actuator
J002 Rear Wiper Motor J005 Rear Hatch Ajar Switch
J003 License Lamp J006 Rear Window Defrost Grid
Rear Hatch Wire Harness #2- Inline
J101 to Rear Hatch Wire Harness #1
Rear Hatch Wire Harness #2- Ground Point
J220 Under Rear Wiper Motor

E - ENGINE CONTROL WIRE HARNESS (WITH 4G63/4G64 ENGINE)
Engine Control Wire Harness - Connector

00
E001 Coolant Temperature Indicator E012 Starter Motor
E002 Fuel Injector 1 E013 Crankshaft Position Sensor
E003 Fuel Injector 2 E015 Downstream Oxygen Sensor
E004 Fuel Injector 3 E016 Odometer Sensor
E005 Fuel Injector 4 E017 Upstream Oxygen Sensor
E006 Knock Sensor E018 Generator
E007 Throttle Position Sensor E019 Generator
E008 Canister Solenoid Valve E020 Ignition Coil
E009 Idle Air Control E021 Engine Coolant Temperature Sensor
Manifold Absolute Pressure/Intake Air E022 A/C Clutch Field Coil

E010
Temperature (MAP/IAT) Sensor
E011 Back-up Lamp Switch
E024 Engine Oil Pressure Switch
Engine Control Wire Harness - Inline

E102 to Instrument Panel Wire Harness E103 to instrument Panel Wire Harness
71
Engine Control Wire Harness - Ground Point
71
E201 Transmission Holder
E - ENGINE CONTROL WIRE HARNESS (WITH BJ493ZQ3 ENGINE)

E - ENGINE ROOM SUB-HARNESS
Engine Control Wire Harness - Connector

E025 Fuel Injector 1 E035 Mass Air Flow Sensor
E026 Fuel Injector 2 E036 High Pressure Pump Solenoid Control Valve
E027 Fuel Injector 3 E037 Cooling Fan Temperature Sensor
E028 Fuel Injector 4 E038 Engine Coolant Temperature Sensor
E029 Preheat Plug E039 Engine Oil Pressure Switch
E030 Preheat Plug E040 Coolant Temperature Indicator
E031 Preheat Plug E041 Common Rail Pressure Sensor
E032 Preheat Plug E042 Crankshaft Position Sensor
E033 Preheat Interface E050 Engine Control Module
E034 Camshaft Position Sensor

Engine Control Wire Harness - Inline

71
Engine Room Sub-harness - Connector
E302 Generator E304 Generator 71
E303 Generator E305 A/C Clutch Field Coil
Engine Room Sub-harness - Inline
E400 to Engine Room Wire Harness

F - ROOF WIRE HARNESS

L - CHASSIS WIRE HARNESS LH
Roof Wire Harness - Connector

F001 Front Indoor Lamp F005 Sliding Roof Control Switch
F003 Sliding Roof Control Motor F006 Antenna Amplifier
F004 Rear Indoor Lamp F007 Sliding Roof Control Module
Roof Wire Harness - Inline

F101 to Instrument Panel Wire Harness F104 to Rear Hatch Wire Harness #1
F102 to Instrument Panel Wire Harness F105 to Rear Evaporator Wire Harness
F103 to Rear Hatch Wire Harness #1

Roof Wire Harness - Ground Points

F205 Above Rear Window RH F236 Above Rear Window RH
71
Chassis Wire Harness LH - Connector
L001 Front Door Ajar Switch LH L005 Fuel Level Sensor 71
L002 Sliding Door Lock Actuator LH L006 Rear Wheel Speed Sensor RH
L003 Sliding Door Step Lamp LH L007 Rear Wheel Speed Sensor LH
L004 Fuel Pump L008 Water Valve
Chassis Wire Harness LH - Inline

L101 to Instrument Panel Wire Harness
F - ROOF SUB-HARNESS (REAR EVAPORATOR WIRE HARNESS)
Roof Sub-Harness - Connector

F301 Rear Intake Sensor F306 Rear Evaporator Motor RH
F302 Rear Temperature Control Switch Rear Evaporator Control Panel

F307
Illumination LH
F303 Rear Evaporator Fuse Box
Rear Evaporator Control Panel
F308
F304 Rear Evaporator Resistor Illumination RH
F305 Rear Evaporator Motor LH F309 Rear Evaporator Blower Switch
Roof Sub-Harness - Inline
F401 to Roof Wire Harness


71
K - CHASSIS WIRE HARNESS RH
71
Rear Body Wire Harness RH - Connector

G001 Sliding Door Ajar Switch RH G004 Cargo Lamp
G002 Rear Speaker RH G005 Rear Combination Lamp RH
G003 Double Diode G007 Sliding Door Step Lamp RH
Rear Body Wire Harness RH - Inline

G101 to Front Body Wire Harness G104 to Rear Body Wire Harness LH
G102 to Front Body Wire Harness G105 to Front Body Wire Harness

Rear Body Wire Harness RH - Ground Point
G201 Above Rear Wheelhouse RH
Rear Body Wire Harness LH - Connector

H001 Sliding Door Ajar Switch LH H007 Rear Heater Switch (Rear Control)
H002 Rear Speaker LH H008 Rear Heater Blower Motor
H005 Rear Combination Lamp LH H009 Rear Heater Control Panel Illumination
H006 Rear Heater Blower Switch
Rear Body Wire Harness LH - Inline

H101 to Rear Body Wire Harness RH H102 to Rear Fog Lamp Wire Harness
Rear Body Wire Harness LH- Ground Point
H201 Above Rear Wheelhouse LH
Chassis Wire Harness RH - Connector

K001 Rear Evaporator Solenoid K004 Back-up Lamp Switch
K002 Front Door Ajar Switch RH K005 Odometer Sensor
K003 Sliding Door Lock Actuator RH K006 Vacuum Alarm
Chassis Wire Harness RH - Inline
K101 to Rear Body Wire Harness RH

M - FRONT DOOR WIRE HARNESS RH
71
71
Front Door Wire Harness RH - Connector

M001 Front Door Lock Actuator RH M004 Front Power Window Motor RH
M002 Front Power Window Switch RH M005 Outside Mirror RH
M003 Front Speaker RH
Front Door Wire Harness RH - Inline

M101 to Instrument Panel Wire Harness M103 to Instrument Panel Wire Harness
M102 to Instrument Panel Wire Harness

Front Door Wire Harness LH - Connector

N001 Outside Mirror Remote Control Switch N004 Front Power Window Motor LH
Main Power Window and Door Lock/ N005 Front Speaker LH

N002
Unlock Switch
N006 Front Door Lock Actuator LH
N003 Outside Mirror LH
Front Door Wire Harness LH - Inline

N102 to Instrument Panel Wire Harness N104 to Instrument Panel Wire Harness
N103 to Instrument Panel Wire Harness

Q - FRONT BODY WIRE HARNESS
71
71
Front Body Wire Harness - Connector

Q001 Rear Heater Switch (Rear Control) Q006 Parking Brake Switch
Q002 Rear Heater Control Panel Illumination Q007 Rear Heater Blower Switch
Q003 Rear Heater Blower Motor Engine Control Module

Q010
Q004 Seat Belt Buckle Switch
Q005 In-vehicle Temperature Sensor
Front Body Wire Harness - Inline

Q101 to Rear Body Wire Harness RH Q105 to Rear Body Wire Harness RH
Q102 to Rear Body Wire Harness RH to Instrument Panel Wire Harness

Q106
to Instrument Panel Wire Harness
Q103 to Instrument Panel Wire Harness
(with 4G63/4G64 Engine) Q107
to Instrument Panel Wire Harness
Q104
MEMO
COMMUNICATION
81
HORN ................................................................................................. 81-1
COMPONENTS ........................................................................... 81-2
REPLACEMENT .......................................................................... 81-3 81
COMBINED DISPLAY........................................................................ 81-4
COMPONENTS ........................................................................... 81-4
REPLACEMENT .......................................................................... 81-5
REVERSE RADAR............................................................................. 81-6
COMPONENTS ........................................................................... 81-7
REPLACEMENT .......................................................................... 81-8
COMMUNICATION SYSTEM - HORN 81-1
HORN
COMMUNICATION SYSTEM

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely 81
cause of the problem. Check each part in order. If necessary, replace these parts.

Chapter 81 communication system - horn, 81
1. Horn (Damaged) replacement
2. Combination switch assy Chapter 51 steering column - combination switch

(Damaged) assy, replacement
Horn is inoperative
Chapter 51 steering column - steering wheel assy,
3. Horn switch (Damaged) overhaul
4. Harness (Damaged) -
1. Combination switch assy Chapter 51 steering column - combination switch

(Damaged) assy, replacement
Horn is always on Chapter 51 steering column - steering wheel assy,

2. Horn switch (Damaged) overhaul
3. Harness (Damaged) -
81-2 COMMUNICATION SYSTEM - HORN
COMPONENTS
1 Bolt 3 Bass Horn
2 Alt Horn
COMMUNICATION SYSTEM - HORN 81-3
REPLACEMENT
1. REMOVE HORN SWITCH. (Refer to “Chapter 51 steering cloumn - steering wheel assy,
overhaul”)
81
2. REMOVE HORN.
(a) Disconnect the horn connectors.
81
(b) Remove 2 retaining bolts of the horns, then take out 2

horns.
3. INSTALL HORN SWITCH. (Refer to “Chapter 51 steering cloumn - steering wheel assy,
overhaul”)
4. INSTALL HORN.
(a) Tighten 2 retaining bolts of 2 horns.
(b) Connect the horn connectors.

81-4 COMMUNICATION SYSTEM - COMBINED DISPLAY
COMBINED DISPLAY
COMPONENTS
1 Cigarette Lighter Assy 5 Electronic Clock Assy (Orange Backlight)
2 12V Power Point Socket (Green Backlight) 6 Combined Display (Green Backlight)
3 12V Power Point Socket (Orange Backlight) 7 Screw
4 Electronic Clock Assy (Green Backlight) 8 Combined Display

COMMUNICATION SYSTEM - COMBINED DISPLAY 81-5
REPLACEMENT
1. REMOVE COMBINED DISPLAY.
(a) Using a screwdriver, pry up the combined display cover 81
and remove the combined display cover.
NOTE
Use slotted screwdriver to avoid damaging the surface.
(b) Remove the retaining screws of the combined display.
81
(c) Disconnect the combined display connector.
2. INSTALL COMBINED DISPLAY.

(a) Connect the combined display connector.
(b) Tighten the retaining screws of the combined display.
(c) Position the combined display cover properly and slap it
by hand to make clips in lock position.
81-6 COMMUNICATION SYSTEM - REVERSE RADAR
REVERSE RADAR
Use the table below to help you find the cause of the problem. The numbers indicate the priority of
the likely cause of the problem. Check each part in order. If necessary, replace these parts.

Chapter 81 communication system
1. Buzzer (Damaged) - reverse radar, replacement
There is no chime within specified 2. Wire between sensor and Chapter 04 diagnostics - reverse
distance controller (Damaged) radar.

3. Controller (Damaged) - reverse radar, replacement

1. Sensor (Incorrect installation) - reverse radar, replacement
Chime sounds when the vehicle is Chapter 81 communication system

out of specified distance 2. Sensor (Damaged) - reverse radar, replacement


1. Combined display (Damaged) - combined display, replacement
No chime in combined display
COMMUNICATION SYSTEM - REVERSE RADAR 81-7
COMPONENTS
81
81
1 Reverse Radar Sensor Assy 3 Bolt
2 Reverse Radar Controller Assy 4 Rear Bumper

81-8 COMMUNICATION SYSTEM - REVERSE RADAR
REPLACEMENT
REVERSE RADAR SENSOR
1. REMOVE REAR BUMPER. (Refer to “Chapter 88 exterior and interior trim - rear bumper,
replacement”)
2. REMOVE REVERSE RADAR SENSOR.
(a) Disconnect the reverse radar sensor connector.
(b) Using a screwdriver, pry up the reverse radar sensor.

NOTE
Do not damage the painted surface of rear bumper.
3. INSTALL REVERSE RADAR SENSOR.

(a) Position the reverse radar sensor properly.
(b) Connect the reverse radar sensor connector.
4. INSTALL REAR BUMPER. (Refer to “Chapter 88 exterior and interior trim - rear bumper,
replacement”)
5. CHECK AFTER INSTALLED. (Refer to “Chapter 04 diagnostics reverse radar system,check”)
COMMUNICATION SYSTEM - REVERSE RADAR 81-9
REVERSE RADAR CONTROLLER

NOTE
Reverse radar controller is located above the accelerator pedal. Remove the steering column lower
cover if necessary. 81
1. REMOVE REVERSE RADAR CONTROLLER.

(a) Remove the retaining bolts of the reverse radar
controller. 81
(b) Disconnect the reverse radar controller connector.
2. INSTALL REVERSE RADAR CONTROLLER.

(a) Connect the reverse radar controller connector.
(b) Install the retaining bolts of the reverse radar controller.
3. CHECK AFTER INSTALLED. (Refer to “Chapter 04 diagnostics reverse radar system, check”)
MEMO
WINDSHIEDLD
82
POWER WINDOW.............................................................................. 82-1
COMPONENTS ........................................................................... 82-1
INSPECTION ............................................................................... 82-2
REPLACEMENT .......................................................................... 82-3 82
WINDSHIELD ..................................................................................... 82-8
COMPONENTS ........................................................................... 82-8 82
REPLACEMENT .......................................................................... 82-9
REAR WINDOW GLASS.................................................................. 82-14 82
COMPONENTS ......................................................................... 82-14
REPLACEMENT ........................................................................ 82-15
SIDE WINDOW GLASS ................................................................... 82-17
COMPONENTS ......................................................................... 82-17
REPLACEMENT ........................................................................ 82-18
OUTSIDE MIRROR .......................................................................... 82-20
COMPONENTS ......................................................................... 82-20
REPLACEMENT ........................................................................ 82-21
REAR VIEW MIRROR ...................................................................... 82-26
COMPONENTS ......................................................................... 82-26
REPLACEMENT ........................................................................ 82-27
REAR LOWER VIEW MIRROR........................................................ 82-30
COMPONENTS ......................................................................... 82-30
REPLACEMENT ........................................................................ 82-31
WINDSHIELD - POWER WINDOW 82-1
POWER WINDOW
WINDSHIELD
COMPONENTS
82
82
1 Front Power Window Motor RH 3 Front Power Window Motor LH
2 Bolt
82-2 WINDSHIELD - POWER WINDOW
INSPECTION
NOTE
Inspect the RH side by the same procedures as the LH side.
1. CHECK POWER WINDOW MOTOR FOR DEFORMATION
(a) If there is any deformation, replace it with a new one.
2. CHECK ROLLER FOR WEAR AND DEFORMATION.
(a) If there are any wear and deformation, replace the power window motor with a new one.
3. CHECK BASIC FUNCTION (MANUAL OPERATION)
(a) Turn the ignition switch ON.
• Check if the door glass moves up when each window switch of the main power window and door lock/
unlock switch is turned UP and moves down when each window switch is turned DOWN.
• Check if the door glass moves up when window switch of each main power window and door lock/
unlock switch is turned UP and moves down when each window switch is turned DOWN.
• Check that the driver’s door glass and other door glass do not operate when the window lock switch is
turned LOCK.
REPLACEMENT
NOTE
82
1. TURN IGNITION SWITCH OFF
2. REMOVE FRONT DOOR CONTROLLER COVER LH.

(a) Remove 2 retaining screws of the front door controller
LH.
(b) Using a screwdriver, pry up the front door controller 82
cover.
(c) Disconnect 2 connectors.
3. REMOVE FRONT DOOR LOCK INNER HANDLE

ASSY LH.
(a) Remove the retaining screw.
(b) Remove 2 door lock connecting rods, then remove front

door inner handle LH.
4. REMOVE FRONT DOOR INNER GUARD PLATE ASSY

LH.
(a) Using a screwdriver, pry out the front door inner triangle
plate LH.
(b) Using a screwdriver, pry out the front door inner guard
plate assy LH.
5. REMOVE FRONT POWER WINDOW MOTOR LH.

(a) Remove 2 screws and 1 bolt and remove the handle
bracket.
(b) Remove front door water-proof film.
(c) Turn the ignition switch ON and connect the front door
controller connectors. Lower the glass to a proper
position, and remove 2 retaining bolts of the power
window motor LH.
(d) Carefully take out the glass.
(e) Turn the ignition switch OFF and disconnect the front
door controller connector.
(f) Disconnect the connector of the front power window

motor LH.
82
82
(g) Remove 5 retaining bolts of the front power window
motor LH.
(h) Carefully take out front power window motor LH.
6. INSTALL FRONT POWER WINDOW MOTOR LH.

(a) Position the front power window motor LH properly.
(b) Tighten 5 retaining bolts of the front power window motor
LH.
Torque: 7 ~ 10 N·m
(c) Connect the connector of the front power window motor

LH.
(d) Position the glass properly.

(e) Tighten 2 retaining bolts of the power window motor LH.
Torque: 7 ~ 10 N·m
(f) Install front door water-proof film.
(g) Position the handle bracket properly and tighten 2

screws and 1 bolt .
Torque: 7 ~ 10 N·m
7. INSTALL FRONT DOOR INNER GUARD PLATE ASSY

LH.
(a) Position the front door inner guard plate assy LH properly
and slap it by hand until the clips lock into position.
NOTE
Must use new clips when installing the guard plate.
(b) Position the front door inner triangle plate LH properly

and slap it by hand until the clips lock into position.
NOTE
Must use the new clips when installing the triangle plate.
8. INSTALL FRONT DOOR LOCK INNER HANDLE ASSY

LH.
(a) Install 2 door lock connecting rods, then install front door
inner handle LH.
(b) Tighten the retaining screw.
82
82
9. INSTALL FRONT DOOR CONTROLLER COVER LH.
(b) Position the front door controller cover properly.

(c) Tighten 2 retaining screws of the front door controller LH.
82-8 WINDSHIELD - WINDSHIELD
WINDSHIELD
COMPONENTS
1 Windshield Assy 3 Windshield Weatherstrip
2 Windshield
WINDSHIELD - WINDSHIELD 82-9
REPLACEMENT
1. REMOVE ENGINE HOOD. (Refer to “Chapter 87 engine hood and doors - engine hood,
replacement”)
82
2. REMOVE FRONT WIPER ARM ASSY. (Refer to “Chapter 65 wiper and washer - wiper assy,
replacement”)
3. REMOVE WINDSHIELD LOWER TRIM. (Refer to “Chapter 65 wiper and washer - front wiper link
4. REMOVE REAR VIEW MIRROR ASSY. (Refer to “Chapter 82 windshield - rear view mirror,
replacement”) 82
5. REMOVE A PILLAR UPPER INNER GUARD BOARD. (Refer to “Chapter 88 exterior and interior
trim - side wall guard board, replacement”)
6. REMOVE WINDSHIELD.
(a) Using a special tool, remove the windshield moulding
outside.
(b) Mark the windshield and body position as shown in the

illustration.
NOTE
It is no need to mark if the windshield is not resued.
(c) Insert the piano wire between the body and the glass.
(d) Attach wooden blocks to both ends of the piano wire.
(e) Pull the piano wire around the glass and cut off the
sealant.
NOTE
• To prevent vehicle paint damage, use adhesive tape
on painted surfaces during windshield removal.
• Place a plastic cover between the piano wire and the
instrument panel to prevent the instrument panel
from being scuffed when removing the glass.
(f) Using 2 suction cups, remove the windshield.

NOTE
• Be carefully not to drop off the windshield.
• Leave as much sealant as possible on the body
when removing the front windshield.
7. CLEAN WINDSHIELD.
(a) Remove the sealant on the windshield with a knife.
NOTE
Do not damage the windshield.
(b) Clean the windshield outer circle with cleaning solvent.
NOTE
• Do not touch the glass surface after cleaning.
• Even if you use new windshield, you should also
clean the windshield with cleaning solvent.
8. CLEAN BODY SURFACE.

(a) Remove the rough harden sealant left on the body with a
knife and clean with a rag soaked with cleaning slovent.
NOTE
• Do not damage the body.
• Even if the entire sealant has been cleared, you
should also clean the body surface.
(b) Cut the sealant with the knife around the glass frame.
Leave 2 mm in thickness of sealant.
NOTE
Do not completely cut curing sealant without necessary.
Do not damage the surface of the body paint. If the paint is
damaged, brush paint or antirusting paint on the damaged
surface.
(c) Clean the windshield primer with the alcohol.
82
82
(d) Apply a layer of primer at the outside of the windshield.
NOTE
• Do not touch the contact surface by hand after
applying the primer.
• Do not brush body primer on the windshield.
• Do not touch water, dust on the brushing face.
9. INSTALL WINDSHIELD.
(a) Position the windshield preperly.
• Position the windshield properly with suction cup.
• Check and ensure the contact surface of the windshield
edge is flat.
• Align the reference marks on the glass and the body.
(b) Apply the primer on the body installing surface.

NOTE
• Do not apply too much primer.
• Dry the primer coat for 5 minutes or more.
• Do not save the opened primer for later use.
• Wipe the excess primer off with a clean rag before it
dries.
(c) Apply the sealant with sealer gun.
NOTE
• Do not apply too much sealant.
• Wipe the excess sealant off with a clean rag before it
dries.
(d) Install windshield.

• Using a suction cup, position the glass so that the
reference marks are aligned. Press it in gently along the
rim.
• Lightly press the glass front surface for close contact.
• Using a scraper, remove any excess or protruding
sealant.
• Fasten the glass with rubber tape before the sealant has
hardened.
NOTE
• Remove the rubber tape after 4 hours later.
• Check that the stoppers are attached to the body
correctly.
• Check the clearance between the body and glass.
10. INSTALL WINDSHIELD MOULDING OUTSIDE.
(a) Install a new windshield moulding to the windshield glass before the sealant has hardened.
(b) Hold the windshield glass in place securely with protective tape or equivalent until the sealant has
completely hardened.
(c) Using a scraper, remove any excess or proturding sealant before the sealant has hardened.
11. INSPECT FOR WATER LEAKAGE.

(a) Perform the leakage test after the hardening period.
(b) Seal any leaks with the porper sealant.
82
82
12. INSTALL FRONT WIPER ARM ASSY. (Refer to “Chapter 65 wiper and washer - wiper assy,
replacement”)
13. INSTALL WINDSHIELD LOWER TRIM. (Refer to “Chapter 65 wiper and washer - front wiper link
14. INSTALL ENGINE HOOD. (Refer to “Chapter 87 engine hood and doors - engine hood,
replacement”)
15. INSTALL REAR VIEW MIRROR ASSY. (Refer to “Chapter 82 windshield - rear view mirror,
replacement”)
16. INSTALL A PILLAR UPPER INNER GUARD BOARD. (Refer to “Chapter 88 exterior and interior
trim - side wall guard board, replacement”)
82-14 WINDSHIELD - REAR WINDOW GLASS
REAR WINDOW GLASS

COMPONENTS
1 Rear Hatch Handle 10 Bolt
2 Rear Hatch Middle Guard Board LH 11 Rear Hatch Concave Limiting Device
3 Rear Hatch Upper Guard Board Assy 12 Bolt
4 Rear Hatch Middle Guard Board RH 13 Rear Hatch Convex Limiting Device
5 Rear Window Glass Assy 14 Lower Damping Block
6 Rear Hatch Lower Inner Guard Board 15 License Plate Lamp Decoration Assy
7 Rear Hatch Lower Waterproof Film 16 Hatch Bar Assy RH
8 Plastic Snap Button 17 Bolt
9 Hatch Bar Assy LH 18 Spoiler Assy

WINDSHIELD - REAR WINDOW GLASS 82-15
REPLACEMENT
1. REMOVE SPOILER ASSY. (Refer to “Chapter 88 exterior and interior trim - spoiler assy,
replacement”)
82
2. REMOVE REAR WIPER ARM ASSY. (Refer to “Chapter 65 wiper and washer - wiper assy,
replacement”)
3. REMOVE REAR HATCH LOWER INNER GUARD BOARD ASSY. (Refer to “Chapter 88 exterior
and interiror trim - vehicle door inner guard board, replacement”)
4. DISCONNECT REAR WINDOW DEFROST GRID CONNECTOR.
5. REMOVE REAR WINDOW GLASS BY THE SAME PROCEDURES AS FRONT WINDSHIELD. 82
6. INSTALL REAR WINDOW GLASS.
(a) Cut the sealant with the knife around the glass bracket. Leave 2 mm in thickness of sealant.
NOTE
Do not completely cut curing sealant without necessary. Do not damage the surface of the body paint.
If the paint is damaged, brush paint or antirusting paint on the damaged surface.
(b) Remove the rough harden sealant left on the body with a knife and clean with a rag soaked with
cleaning slovent.
(c) Mark the rear window and body position as shown in the
illustration.
(d) Stick rubber fender around the glass to avoid sealant

spilled when installing.
(e) Install rear window glass insertion strip without any
clearence.
(f) Apply a layer of primer at the outside of the rear window

glass insertion strip.
NOTE
(g) Apply the sealant around the window glass.

82-16 WINDSHIELD - REAR WINDOW GLASS
NOTE
Apply sealant within 5 minutes after applying the primer.
(h) Apply the primer on the glass installing surface. Install

rear window glass 10 minutes later.
(i) Using 2 suction cups, position the glass so that the

rim.
(j) Using a scraper, remove any excess or protruding

sealant.
(k) After one hour, perform the test for rear window water
leakage.
(l) Seal any leaks with the porper sealant.

NOTE
• After installing rear window glass, wait an hour or more to let sealant hardened.
• After installing rear window glass, place the vehicle on a flat ground for more than four hours. If
need to run the car this moment, slowly drive the car in eight hours.
• After installing rear window glass, do not be over-load in two to three days. (As drive in
irregular, uneven road.)
WINDSHIELD - SIDE WINDOW GLASS 82-17
SIDE WINDOW GLASS

COMPONENTS
82
82
1 Sliding Door Glass Weatherstrip LH 4 Decorative cover
2 Rear Sliding Door Glass Weatherstrip LH 5 Rear Sliding Door Glass ASSY LH
3 Sliding Door Glass Assy LH

82-18 WINDSHIELD - SIDE WINDOW GLASS
REPLACEMENT
1. REMOVE SIDE WALL INNER GUARD BOARD. (Refer to “Chapter 88 exterior and interior trim -
side wall inner guard board, replacement”)
2. REMOVE SIDE WINDOW GLASS BY THE SAME PROCEDURES AS WINDSHIELD.
3. INSTALL SIDE WINDOW GLASS.
(a) Cut the sealant with the knife around the glass frame. Leave 2 mm in thickness of sealant.
NOTE
Do not completely cut curing sealant without necessary. Do not damage the surface of the body paint.
If the paint is damaged, brush paint or antirusting paint on the damaged surface.
(b) Remove the rough harden sealant portions on the body with a knife and clean with a rag soaked with
cleaning solvent.
(c) Mark the side window and body position as shown in the
illustration.
(d) Stick rubber fender around the glass to avoid sealant

spilled when installing.
(e) Install side window glass insertion strip without any
clearance.
(f) Apply a layer of primer at the outside of the side window

glass insertion strip.
NOTE
(g) Apply the sealant around the window glass.

NOTE
Apply sealant within 5 minutes after applying the primer.
WINDSHIELD - SIDE WINDOW GLASS 82-19
(h) Apply the primer on the glass installing surface. Install

side window glass 10 minutes later.
82
82
(i) Using 2 suction cups, position the glass so that the
rim.
(j) Using a scraper, remove any excess or protruding

sealant.
(k) After one hour, perform the test for rear window water
leakage.
(l) Seal any leaks with the porper sealant.

NOTE
• After installing side window glass, wait one hour or more to let sealant hardened.
• After installing side window glass, place the vehicle on a flat ground for more than four hours. If
need to run the car this moment, slowly drive the car in eight hours.
• When all the windows are closed, do not close the door furiously.
• After installing side window glass, do not be over-load in two to three days. (As drive in
irregular, uneven road.)
82-20 WINDSHIELD - OUTSIDE MIRROR
OUTSIDE MIRROR
COMPONENTS
1 Outside Mirror Assy LH 3 Outside Mirror Assy RH
2 Screw
WINDSHIELD - OUTSIDE MIRROR 82-21
REPLACEMENT
NOTE
82
1. REMOVE FRONT DOOR INNER GUARD BOARD LH. (Refer to “Chapter 88 exterior and interior
trim - vehicle door inner guard board, replacement”)
2. DISCONNECT CONNECTOR.
82
3. REMOVE 2 RETAINING SCREWS.

4. REMOVE OUTSIDE MIRROR ASSY LH.
5. DISASSEMBLE OUTSIDE MIRROR LH.

(a) Remove 3 screws from the outside mirror base.
(b) Remove the outside mirror body.
(c) Remove the outside mirror glass.

(d) Remove 3 retaining screws of the outside mirror motor.
(e) Disconnect the connector of the outside mirror motor.
(f) Disconnect the connector of the turn signal lamp in

outside mirror.
(g) Remove 2 retaining screws from the folding bracket.
(h) Remove the screw from the folding bracket base.
(i) Remove 2 screws from the folding bracket base.

(j) Remove the folding bracket.
(k) Remove 2 retaining screws from the turn signal lamp in

outside mirror.
82
82
(l) Remove the turn signal lamp in outside mirror.
6. ASSEMBLE OUTSIDE MIRROR.

(a) Position the turn signal lamp in outside mirror properly.
(b) Tighten 2 retaining screws to the turn signal lamp in

outside mirror.
(c) Position the folding bracket properly.

(d) Tighten 2 screws to the folding bracket base.
(e) Tighten 2 screws to the folding bracket base.
(f) Tighten 2 screws to the folding bracket.
(g) Connect the connector of the turn signal lamp in outside

mirror.
(h) Connect the connector of the outside mirror motor.
(i) Tighten 3 retaining screws of the outside mirror motor.

(j) Install the outside mirror glass.
(k) Position the outside mirror properly.

(l) Tighten 3 screws to the outside mirror base.
82
82
7. INSTALL OUTSIDE MIRROR ASSY LH.
(a) Tighten 2 retaining screws.
(b) Connect the connector of the outside mirror assy LH.
8. INSTALL FRONT DOOR INNER GUARD BOARD LH. (Refer to “Chapter 88 exterior and interior
trim - vehicle door inner guard board, replacement”)
82-26 WINDSHIELD - REAR VIEW MIRROR
REAR VIEW MIRROR

COMPONENTS
1 Rubber Pipe 3 Rear View Mirror Assy
2 Screws
WINDSHIELD - REAR VIEW MIRROR 82-27
REPLACEMENT
1. REMOVE FRONT INDOOR LAMP.
(a) Using a screwdriver, pry out the front indoor lamp cover. 82
82
(b) Using a screwdriver, pry out the front indoor lamp

mounting screw cover.

(d) Remove the front indoor lamp.
(e) Disconnect the connector of the front indoor lamp.

82-28 WINDSHIELD - REAR VIEW MIRROR
2. REMOVE REAR VIEW MIRROR.

(a) Remove 3 mounting screws and remove the rear view
mirror.
3. INSTALL REAR VIEW MIRROR.

(a) Position the rear view mirror properly and tighten 3
screws.
(b) Connect the connector of the front indoor lamp.
(c) Position the front indoor lamp properly

(d) Tighten 2 retaining screws to the front indoor lamp.
(e) Install the front indoor lamp mounting screw cover.

WINDSHIELD - REAR VIEW MIRROR 82-29
(f) Install the front indoor lamp cover.
82
82
82-30 WINDSHIELD - REAR LOWER VIEW MIRROR
REAR LOWER VIEW MIRROR

COMPONENTS
1 Screw 2 Rear Lower View Mirror Assy

WINDSHIELD - REAR LOWER VIEW MIRROR 82-31
REPLACEMENT
1. REMOVE REAR LOWER VIEW MIRROR.
(a) Using a screwdriver, pry out the rear lower view mirror 82
cover.
82
(b) Remove 4 retaining screws from the rear lower view

mirror.
(c) Remove the rear lower view mirror.
2. INSTALL REAR LOWER VIEW MIRROR.

(a) Position the rear lower view mirror properly and tighten 4
retaining screws.
(b) Install the rear lower view mirror cover.

MEMO
INSTRUMENT PANEL
83
DASHBOARD..................................................................................... 83-1
PRECAUTION.............................................................................. 83-1
COMPONENTS ........................................................................... 83-2
REPLACEMENT .......................................................................... 83-4 83
MIDDLE PLATFORM ....................................................................... 83-27
COMPONENTS ......................................................................... 83-27
REPLACEMENT ........................................................................ 83-28
INSTRUMENT CLUSTER ................................................................ 83-31 83
PRECAUTION............................................................................ 83-31
PROBLEM SYMPTOMS TABLE................................................ 83-32
COMPONENTS ......................................................................... 83-35
REPLACEMENT ........................................................................ 83-36
INSTRUMENT PANEL - DASHBOARD 83-1
DASHBOARD
INSTRUMENT PANEL
PRECAUTION
1. WHEN REMOVING INSTRUMENT PANEL, CLOCK IN INSTRUMENT CLUSTER ARE CLEAR. 83
NOTE
2. WHEN REMOVING INSTRUMENT PANEL, MEMORY OF THE AUDIO SYSTEM WILL BE LOST.
NOTE
When work is finished, reset the audio systems as they were before. (Refer to “OWNER’S MANUAL”)
3. POWER OFF.
(a) Before removing or installing any electrical devices, please disconnect the battery negative cable to 83
prevent damage to the device or personal injury.
(b) Make sure ingition switch is OFF if no specific instructions.
83-2 INSTRUMENT PANEL - DASHBOARD
COMPONENTS
1 Defrosting Air Duct 15 Defrosting Vent Assy RH
2 Defrosting Distraction Air Duct 16 Glove Box Assy RH
3 Dashboard Body 17 Glove Box Mounting Assy RH
4 Defrosting Vent Assy LH 18 A/C Air Outlet Pipe Assy RH
5 A/C Air Outlet Pipe Assy LH 19 Side Vent Assy RH
6 Side Vent Assy LH 20 Middle Air Outlet Assy
7 Electric Appliance Switch Panel LH 21 Middle Panel Assy
8 Clamp Middle Glove Box Outer Guard Board

22
Assy
9 Steering Column Lower Cover
23 Ashtray Assy
10 Ignition Lock Protecting Ring
24 Instrument Cluster Cover Assy
11 Evaporator Lower Guard Board RH
25 Glove Box Axis Pin
12 Lower Guard Board RH
Evaporator Guard Board Retaining
13 Middle Glove Box Assy 26
Bracket
14 Middle Upper Cover Assy
REPLACEMENT
1. PAY ATTENTION TO VEHICLE SRS AIRBAG.
(a) Some operations of this chapter will affect the SRS airbag. Before these operations, please read the
precaution for the SRS airbag. 83
2. PLACE VEHICLE ON LEVEL OR LIFTER AND FACE TIRES STRAIGHT AHEAD.
3. TURN INGITION SWITCH OFF.

NOTE
When disconnecting or connecting the battery cables,
please turn off the ignition switch first and lighting switch 83
and loosen the cable nut completely. Do not pry up the
cable when peforming these operations.
5. REMOVE HORN SWITCH. (Refer to “Chapter 51 steering column - steering wheel assy,
overhaul”)
overhaul”)
7. REMOVE COMBINATION SWITCH ASSY.

(b) Remove combination switch upper and lower covers.

(c) The vehicle equips with airbag:

• Remove the clock spring with 4 screws.
(d) Disconnect 2 conectors.

• Disconnect the front combination lamp dimmer switch
connector.
• Disconnect the wiper and washer switch connector.
(e) Remove 3 screws.
(f) Remove the combination switch assy.

8. REMOVE INSTRUMENT CLUSTER.

(a) Remove the instrument cluster cover.
83
(b) Remove 4 retaining screws of the instrument cluster.

83
(c) Turn the instrument cluster.

(d) Disconnect the connecotor.
(e) Take out the instrument cover.
9. REMOVE 5 RETAINING SCREWS BEHIND INSTRU-

MENT CLUSTER.
10. REMOVE STEERING COLUMN LOWER COVER.

(a) Pull out the engine hood lock handle.
(c) Pull out the engine hood control handle.

(d) Remove the engine hood control cable.
(e) Remove 3 retaining screws of the steering column lower

cover.
(f) Remove the steering column lower cover.

(g) Disconnect the diagnositic wire harness connector.
83
11. REMOVE ELECTRIC APPLIANCE SWITCH PANEL LH.

(a) Using a screwdriver, pry out the electric appliance switch 83
panel LH.

(c) Remove the electric appliance switch panel LH.
12. REMOVE MIDDLE UPPER COVER.

(a) Using a screwdriver, pry up the middle upper cover.
(b) Remove the middle upper cover.
(c) If it installs the combined display here, refer to “Chapter
81 communication system - combined display, replace-
ment”

(a) Using a screwdriver, pry up the middle panel assy.
(b) Disconnect these connectors.

14. REMOVE MIDDLE AIR OUTLET.

(b) Disconnect the connectors of the hazard switch and
electronic clock.
(c) Remove the middle air outlet.
15. REMOVE AUDIO UNIT.

(a) Remove 4 bolts.
(b) Take out the audio unit.
(c) Disconnect the connector of the audio unit.

(d) Disconnect the connector of the audio antenna.

(e) Carefully store the audio unit to prevent loss.
83
83
16. REMOVE FRONT A/C CONTROLLER ASSY.

(a) Remove 4 retaining screws.
(b) Turn the front A/C controller assy.

• Auto A/C:
Disconnect the connectors.
• Manual A/C:
Disconnect the cables.
(c) Remove the front A/C controller.
17. REMOVE ASHTRAY ASSY.

(a) Press ashtray tab by hand.
(b) Pull out the ashtray assy.
18. REMOVE MIDDLE GLOVE BOX ASSY.

(a) Open the middle glove box.
(b) Using a screwdriver, pry out the glove box axis.
(c) Remove the middle glove box.
19. REMOVE LOWER GUARD BOARD RH.

(b) Using a screwsdriver, pry out the lower guard board RH.
20. REMOVE EVAPORATOR LOWER GUARD BOARD

RH.
(b) Using a screwsdriver, pry out the evaporator lower guard
board RH.
21. REMOVE A PILLAR HANDLE RH.

(a) Using a screwdriver, pry out the handle screw covers.

(c) Remove A pillar handle.
22. REMOVE PASSENGER HANDLE RH.

(a) Using a screwdriver, pry out the passenger handle cover
RH.
83

(c) Remove the passenger handle RH. 83
23. REMOVE A PILLAR UPPER INNER GUARD BOARD

RH.
(a) Using a screwdriver, carefully pry out the clips.
(b) Remove A pillar upper inner guard board RH.
24. REMOVE A PILLAR HANDLE LH, PASSENGER

HANDLE LH AND A PILLAR UPPER INNER GUARD
BOARD LH.
(a) Remove the LH side by the same procedures as the RH
side.
25. REMOVE FRONT DOORFRAME RUBBER STRIPS LH & RH.

26. REMOVE DASHBOARD BODY.

(a) Remove the screw upon the engine hood control handle.
(b) Remove the screw at the dashboard left side.
(c) Remove the screw at the dashboard right side.

(d) Remove 2 nuts behind the middle glove box.
83
(e) Remove 2 screws behind the lower guard board RH. 83
(f) Remove front wiper arm assy. (Refer to “Chapter 65

wiper and washer - wiper assy, replacement”)
(g) Remove windshield lower trim. (Refer to “Chapter 65
wiper and washer - front wiper link assy, replacement”)
(h) Remove the nut below the windshield.

(i) Carefully take out the dashboard body.
NOTE
Because there are many harness in the instrument panel, when
removing the instrument panel, be careful not to hook the
harness, so as not to damage the harness.
27. INSTALL DASHBOARD BODY.

(a) Position the dashboard body properly.
(b) Put the inside harness in order and wait for using when
installing dashboard accessories.
(c) Tighten the nut below the windshield.
(d) Install windshield lower trim. (Refer to “Chapter 65 wiper

and washer - front wiper link assy, replacement”)
(e) Install front wiper arm assy. (Refer to “Chapter 65 wiper
and washer - wiper assy, replacement”)
(f) Tighten 2 screws behind the lower guard board RH.
(g) Tighten 2 nuts behind the middle glove box.

(h) Tighten the screw at the dashboard right side.
83
83
(i) Tighten the screw at the dashboard left side.
(j) Tighten the screw upon the engine hood control handle.
28. INSTALL A PILLAR HANDLE RH.

(a) Tighten 2 screws.
(b) Install 2 handle screw covers.
29. INSTALL PASSENGER HANDLE RH.

(a) Tighten 2 screws.
(b) Install 2 passenger handle screw covers.
30. INSTALL A PILLAR UPPER INNER GUARD BOARD RH.

(a) Position the A pillar upper inner guard board RH properly
with rubber hammer.
31. INSTALL A PILLAR HANDLE LH, PASSENGER

HANDLE LH AND A PILLAR UPPER INNER GUARD
BOARD LH.
83
(a) Install the LH side by the same procedures as the RH
side.
32. INSTALL FRONT DOORFRAME RUBBER STRIPS LH & RH. 83

33. INSTALL EVAPORATOR LOWER GUARD BOARD RH.
(a) Position the evaporator lower guard board RH properly.
34. INSTALL LOWER GUARD BOARD RH.

(a) Position the lower guard board RH properly.
35. INSTALL MIDDLE GLOVE BOX ASSY.

(a) Position the middle glove box assy properly.
(b) Install the glove box axis.
(c) Close the middle glove box.
36. INSTALL ASHTRAY ASSY.

(a) Press ashtray tab by hand.
(b) Position the ashtray properly.
37. INSTALL FRONT A/C CONTROLLER ASSY.

(a) Connect the front A/C controller assy.
• Auto A/C:
Connect the connectors.
• Manual A/C:
Connect the cables.
(b) Position the front A/C controller properly.

(c) Tighten 4 retaining screws.
38. INSTALL AUDIO UNIT.

(a) Connect the connector of the audio unit.
(b) Connect the connector of the audio antenna.
83
83
(c) Position the audio unit porperly.

(d) Tighten 4 bolts.
39. INSTALL MIDDLE AIR OUTLET.

(a) Position the middle air outlet properly.
(b) Connect the connectors of the hazard switch and elec-
tronic clock.
(c) Tighten 5 screws.

(a) Connect the connectors.
(b) Position the front A/C controller assy properly.

(c) Slap the middle panel by hand and the clips lock into
position. Pay attention not to damage the inner harness.
41. INSTALL MIDDLE UPPER COVER ASSY.

(a) Slap the middle upper cover by hand and the clips lock
into position.
(b) If it installs the combined display here, refer to “Chapter
81 communication system - combined display, replace-
ment”
42. INSTALL ELECTRIC APPLIANCE SWITCH PANEL LH.

(b) Install the electric appliance switch panel LH.
43. INSTALL STEERING COLUMN LOWER COVER.

(a) Connect the diagnosis wire harness connector.
(b) Position the steering column lower cover properly.
83
(c) Tighten 3 retaining screws of the steering column lower

cover. 83
(d) Install the engine hood control cable.
(e) Position the engine hood control handle properly.

44. INSTALL 5 RETAINING SCREWS BEHIND INSTRU-

MENT CLUSTER.
45. INSTALL INSTRUMENT CLUSTER.

(a) Connect the connecotor.
(b) Tighten 4 retaining screws of the instrument cluster.
(c) Install the instrument cluster cover.

46. INSTALL COMBINATION SWITCH ASSY.

(a) Install the combination switch assy.
83

83
(c) Connect 2 connectors:

• Connect the front combination lamp dimmer switch
connector.
• Connect the wiper and washer switch connector.
(d) The vehicle with airbag:

• Tighten the clock spring with 4 screws.
CAUTION
• Check for the fracture on the spiral cable, and there
should be no broken on the insulating barrier.
• Make sure the cable rolls smoothly without noise.
NOTE
The cable will rotate more than 5.3 turns.

(e) Install the combination switch upper and lower covers.

NOTE
Make sure the covers are installed properly.
(g) The vehicle with airbag:

Center the clock spring.
• Check that the ignition switch is at the “OFF” position.
• Check that the battery positive and negetive cables are
disconnected.
CAUTION
Do not start the operation within 90 seconds after
disconnecting the cables.
NOTE
There is a label on the clock spring. Follow the instructions
on the label.
• Turn the cable counterclockwise by hands until it
• Rotate the cable clockwise about 2.5 turns to align the

marks.
NOTE
the center.
NOTE
83
clock spring.
overhaul”) 83
overhaul”)
50. INSPECT AFTER INSTALLATION.
(a) Inspect the dashboard switch function and combination switch function.
(b) Inspect airbag warning light. (If equipped, refer to “Chapter 04 diagnostics - supplemental restraint
system, precheck”, “Chapter 04 diagnostics - supplemental restraint system, airbag warning light circuit
malfunction (always light up, when DTC is not detected)”, “Chapter 04 diagnostics - supplemental
restraint system, airbag warning light circuit malfunction (does not light up, when ignition switch is turn
to the "ON" position)”)
83-26 INSTRUMENT PANEL - MIDDLE PLATFORM
MIDDLE PLATFORM
COMPONENTS
1 Middle Gasket 6 Middle Platform Body
2 Side Liner 7 Passenger Zone Air Heater Hood Assy
3 Upper Panel Assy 8 Middle Platform Bracket LH
4 Middle Platform Rear Panel 9 Middle Platform Bracket RH Welding Assy
5 Ashtray Assy 10 Middle Platform Front Bracket

INSTRUMENT PANEL - MIDDLE PLATFORM 83-27
REPLACEMENT
1. REMOVE SHIFT LEVER DUST COVER.
(a) Using a screwdriver, pry out the shift lever dust cover. 83
83
2. REMOVE PARKING BRAKE OPERATION HANDLE
RUBBER SLEEVE.
3. REMOVE MIDDLE PLATFORM BODY.

(a) Remove 2 front-retaining nuts.
.
83-28 INSTRUMENT PANEL - MIDDLE PLATFORM
(b) Remove 2 side-retaining nuts.
(c) Remove 2 both sides retaining screws.

(d) Take out the middle platform.
4. INSTALL MIDDLE PLATFORM BODY.

(a) Position the middle platform body properly.
(b) Tighten 2 both sides retaining screws.
(c) Tighten 2 side-retaining nuts.

INSTRUMENT PANEL - MIDDLE PLATFORM 83-29
(d) Tighten 2 front-retaining nuts.
83
83
5. INSTALL PARKING BRAKE OPERATION HANDLE

RUBBER SLEEVE.
6. INSTALL SHIFT LEVER DUST COVER.

83-30 INSTRUMENT PANEL - INSTRUMENT CLUSTER
INSTRUMENT CLUSTER
PRECAUTION
1. WHEN REMOVING INSTRUMENT PANEL, CLOCK IN INSTRUMENT CLUSTER ARE CLEAR.
NOTE
2. POWER OFF.
(a) Before removing or installing any electrical devices, please disconnect the battery negative cable to
prevent damage to the device or personal injury.
(b) Make sure ingition switch is OFF if no specific instructions.
INSTRUMENT PANEL - INSTRUMENT CLUSTER 83-31

Use the table below to help you to find the cause of the problem. The numbers indicate the
priority of the likely cause of the problem. Check each part in order. If necessary, replace
these parts. 83
SYSTEM

Chapter 04 diagnostics - instrument cluster, the
1. Power, ground circuits instrument cluster is inoperative
The instrument cluster is
inoperative Chapter 04 diagnostics - instrument cluster, the
2. Instrument cluster instrument cluster is inoperative
83
Chapter 04 diagnostics - lighting, problem
1. Instrument cluster illumi- symptoms table
The instrument cluster nation circuits Chapter 83 instrument panel - instrument cluster,
background illumination replacement
is inoperative
Chapter 83 instrument panel - instrument cluster,
2. Instrument cluster replacement
GAUGES

Chapter 04 diagnostics - instrument cluster,
1. Speedometer sensor malfunction in speedometer

Malfunction in speedometer 2. Speedometer circuits malfunction in speedometer

3. Speedometer malfunction in speedometer

1. CKP sensor malfunction in tachometer

Malfunction in tachometer 2. Tachometer circuits malfunction in tachometer

3. Tachometer malfunction in tachometer

1. Fuel level sensor malfunction in fuel gauge

Malfunction in fuel gauge 2. Fuel gauge circuits malfunction in fuel gauge

3. Fuel gauge malfunction in fuel gauge
WARNING LIGHTS
1. Engine electronic control Chapter 04 diagnostics - gasoline/diesel engine

system control system, diagnostic trouble code chart
Malfunction indicator light 2. Malfunction indicator light Chapter 04 diagnostics -gasoline/diesel engine
never/always on circuits control system, diagnostic trouble code chart
Chapter 04 diagnostics -gasoline/diesel engine

3. Instrument cluster control system, diagnostic trouble code chart
1. Engine electronic control Chapter 04 diagnostics - gasoline engine control

system system, diagnostic trouble code chart
SVS indicator light never/ Chapter 04 diagnostics -gasoline engine control

always on (Gasoline) 2. SVS indicator light circuits system, diagnostic trouble code chart
Chapter 04 diagnostics - gasoline engine control

3. Instrument cluster system, diagnostic trouble code chart
Chapter 04 diagnostics - instrument cluster, brake

1. Brake fluid level sensor warning light never/always on

2. Parking brake switch warning light never/always on
Brake warning light
never/always on Chapter 04 diagnostics - instrument cluster, brake
3. Brake warning light cir-
cuits warning light never/always on

4. Instrument cluster warning light never/always on
Chapter 04 diagnostics - anti-lock brake system,

1. ABS system problem symptoms table
ABS warning light never/ Chapter 04 diagnostics -anti-lock brake system,

always on 2. ABS warning light circuits problem symptoms table
Chapter 04 diagnostics -anti-lock brake system,

3. Instrument cluster problem symptoms table
Chapter 04 diagnostics - instrument cluster, door

1. Door ajar switch ajar warning light never/always on
Door ajar warning light 2. Door ajar warning light Chapter 04 diagnostics - instrument cluster, door
never/always on circuits ajar warning light never/always on
Chapter 04 diagnostics - instrument cluster, door

3. Instrument cluster ajar warning light never/always on
Chapter 04 diagnostics - instrument cluster, engine

1. ECT sensor coolant temperature warning light never/always on
2. Engine coolant level Chapter 04 diagnostics - instrument cluster, engine

sensor coolant temperature warning light never/always on
Engine coolant
temperature warning light
3. Engine coolant
never/always on Chapter 04 diagnostics - instrument cluster, engine
temperature warning light
coolant temperature warning light never/always on
circuits
Chapter 04 diagnostics - instrument cluster, engine

4. Instrument cluster coolant temperature warning light never/always on

Chapter 04 diagnostics - supplemental restraint
1. SRS system circuits system,SRS warning light never/always on
83
SRS warning light never/ Chapter 04 diagnostics - supplemental restraint
always on (Gasoline) 2. SRS warning light circuits system,SRS warning light never/always on
Chapter 04 diagnostics - supplemental restraint

3. Instrument cluster system,SRS warning light never/always on
INDICATOR LIGHTS
Symptom Suspect Area Reference 83

1. Enging oil pressure switch engine oil pressure warning light never/
always on

Enging oil pressure warning 2. Enging oil pressure warning engine oil pressure warning light never/
light never/always on light circuits always on

3. Instrument cluster engine oil pressure warning light never/
always on

1. ECT sensor engine coolant temperature indicator light
never on

Engine coolant temperature
2. ECT sensor circuits engine coolant temperature indicator light
indicator light never on
never on

3. Instrument cluster engine coolant temperature indicator light
never on
Chapter 04 diagnostics -lighting, problem

1. Fuses symptoms table

2. Combination switch symptoms table

3. Hazard switch symptoms table
Turn signal/hazard indicator
light never/always on 4. Multi-functional controller (3- Chapter 04 diagnostics - lighting, problem
in-1) symptoms table
5. Turn signal/hazard indicator Chapter 04 diagnostics - lighting, problem

light circuits symptoms table

6. Instrument cluster symptoms table


High beam indicator light 3. Multi-functional controller (3- Chapter 04 diagnostics -lighting, problem
never/always on in-1) symptoms table
4. High beam indicator light cir- Chapter 04 diagnostics -lighting, problem

cuits symptoms table



Front fog lamp indicator light
never/always on Chapter 04 diagnostics - lighting, problem
3. Front fog lamp indicator light
circuits symptoms table




3. Rear fog lamp switch symptoms table
Rear fog lamp indicator light
never/always on 4. Multi-functional controller (3- Chapter 04 diagnostics -lighting, problem
in-1) symptoms table
5. Rear fog lamp indicator light Chapter 04 diagnostics -lighting, problem

circuits symptoms table

LIQUID CRYSTAL DISPLAY

Clock - No display or blurry Chapter 83 instrument panel - instrument 83
display 1. Liquid crystal display cluster, replacement
Chapter 83 instrument panel - instrument

1. Incorrect setup currently cluster, replacement
The clock can not be set
2. Trip odometer and clock Chapter 83 instrument panel - instrument
change button cluster,replacement
Can not switch between clock 1. Trip odometer and clock Chapter 83 instrument panel - instrument
and odometer change button cluster, replacement 83
Odometer - No display or blurry Chapter 83 instrument panel - instrument
display 1. Liquid crystal display cluster, replacement
COMPONENTS
1 Dashboard Body 3 Screw
2 Instrument Cluster 4 Instrument Cluster Cover

REPLACEMENT
NOTE 83
When disconnecting or connecting the battery cables,
please turn off the ignition switch first and lighting switch
and loosen the cable nut completely. Do not pry up the
cable when peforming these operations.
83
2. REMOVE INSTRUMENT CLUSTER.
(a) Remove the instrument cluster cover.
(b) Remove 4 retaining screws of the instrument cluster.
(c) Turn the instrument cluster.

(d) Disconnect the connecotor.
(e) Take out the instrument cover.
3. INSTALL INSTRUMENT CLUSTER.

(a) Connect the connecotor.
(b) Tighten 4 retaining screws of the instrument cluster.
(c) Install the instrument cluster cover.

SEAT
84
SEAT .................................................................................................. 84-1
PRECAUTION.............................................................................. 84-1
DRIVER / ASSISTANT DRIVER SEAT.............................................. 84-2
COMPONENTS ........................................................................... 84-2 84
ADJUSTMENT ............................................................................. 84-3
REMOVAL & INSTALLATION AND
DISASSEMBLY & REASSEMLBY ............................................... 84-8
PASSENGER SEAT......................................................................... 84-25 84
COMPONENTS ......................................................................... 84-25
84
SEAT - SEAT 84-1
SEAT
SEAT
PRECAUTION
1. SEAT SYSTEM PRECAUTION. 84
(a) Never adjust the seat when vehicle is moving.
(b) After adjusting the seat position front and rear, be sure to attempt to slide the seat with track handle
released and make sure the seat is locked completely.
(c) After adjusting the angle of backrest, be sure to attempt to tilt the backrest backward and make sure the
backrest is locked completely.
(d) Never move the vehicle before all pasengers sitting down properly.
(e) When vehicle is moving, make sure the backrest is locked completely. Be sure to wear seat belt
correctly and lean no the backrest. Never sit on a folding seat or in the trunk.
(f) Do not stand and ambulate when vehicle is moving.
84
(g) Never place objects under the seat. Otherwise it will affect the performance of seat adjuster, even
cause the seat slide unexpectedly.
84-2 SEAT - DRIVER / ASSISTANT DRIVER SEAT
DRIVER / ASSISTANT DRIVER SEAT

COMPONENTS
1 Driver Seat Assy 5 Flat Washer
2 Assistant Driver Seat Assy 6 Driver Seat Base Welding Assy
3 Bolt 7 Assistant Driver Seat Base Welding Assy
4 Spring Washer
SEAT - DRIVER / ASSISTANT DRIVER SEAT 84-3
ADJUSTMENT
1. PRECAUTION. (Refer to “Chapter 84 seat - seat, precaution”)
2. PRECAUTION ON DRIVER SEAT ADJUSTMENT.
84
(a) Slide the driver seat backward as much as possible on the premise that the driver can treadle the pedal
comfortably.
(b) If necessary, adjust the angle of driver seat backrest to keep the distance between steering wheel and
your chest above 250 mm.
NOTE
Adjust the steering wheel towards your chest, instead of the head or neck. (Refer to “Chapter 51 steer-
ing column - steering wheel assy, adjustment”)
3. ADJUST HEADREST HEIGHT.

(a) Press the lock button and hold it. 84
(b) Move the headrest up and down to the comfortable posi-

tion.
(c) Release the lock button.

(d) Attempt to move the headrest up and down to make sure

the headrest is locked completely.
NOTE
If hear a “click”, the headrest is locked completely.
4. ADJUST FORE-AND-AFT POSITION.

(a) Pull the track handle up and hold it.
(b) Slide the seat front and rear to the comfortable position.
(c) Release the track handle.
84
84
(d) Attempt to slide the seat front and rear to make sure the
seat is locked completely.
NOTE
If hear a “click”, the seat is locked completely.
5. ADJUST BACKREST RECLINING.

(a) Pull the reclining adjuster handle up.
(b) Tilt the backrest reclining by back to the comfortable

position.
(c) Release the reclining adjuster handle.
84
84
(d) Attempt to tilt the backrest reclining to make sure the

backrest is locked completely.
REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMLBY

WARNING
Be sure to wear gloves when performing operations below.
NOTE
Tape the screwdriver tip before prying parts.
1. PRECAUTION. (Refer to “Chapter 84 seat - seat, precaution”)
2. DISCONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging - bat-
tery, replacement”)
3. REMOVE DRIVER SEAT ASSY.

(a) Slide the driver seat assy foremost.
(b) Using an allen wrench (key), loosen 2 bolts.

(c) Slide the driver seat assy backmost.
84
84
(d) Loosen 2 bolts.
(e) Remove the extinguisher bracket.

(f) Loosen 2 bolts.

CAUTION
• Turn the driver seat assy over backward carefully
and slowly.
• Do not drag the electric buckle wire harness.
• Do not move the tracks to prevent malposition.
(g) Disconnect the electric buckle wire harness connector.
(h) Using a screwdriver, pry the electric buckle wire harness

connector from the driver seat base welding assy.
NOTE
If the connector is broken, replace the electric buckle assy.
(Refer to “Chapter 63 seat belt - buckle assy, replacement”)
(i) Remove the driver seat assy.

WARNING
Care must be taken because the driver seat assy is quite
heavy.
CAUTION
• Do not score surfaces of parts around.
• Do not move the tracks when storing to prevent mal-
position.
4. REMOVE ASSISTANT DRIVER SEAT ASSY.

NOTE
• Remove the assistant driver seat assy by the same procedures as the driver seat assy.
84
• Skip step (e) and (f).
5. REMOVE DRIVER SEAT BASE WELDING ASSY.

(a) Remove 4 clips.
NOTE
• Discard the removed clips.
• Tape the screwdriver tip.
84
(b) Remove the driver seat base trim.
(c) Loosen 4 bolts.
(d) Loosen the nut.

(e) Put the fuel filling door handle into the driver seat base
welding assy through the hole.
(f) Remove the driver seat base welding assy.
6. REMOVE ASSISTANT DRIVER SEAT BASE WELDING ASSY.

NOTE
• Remove the assistant driver seat base welding assy by the same procedures as the driver seat
base welding assy.
• Skip step (d) and (e).
7. DISASSEMBLE DRIVER SEAT ASSY.
CAUTION
Do not move the tracks when performing operations below to prevent malposition.
(a) Pull out the reclining adjuster handle cover.
(b) Loosen the screw.

(c) Remove the reclining adjuster trim cover handle side by

the sequence shown in the illustration.
NOTE
• Move the trim cover backward to separate 2 slots. 84
• Pull the trim cover outward.
• Move forward and remove the trim cover.
84
(d) Loosen the screw.
(e) Remove the reclining adjuster trim cover electric buckle

NOTE
• Move the trim cover backward to separate 2 slots.
• Pull outward and remove the trim cover.
(f) Loosen completely the bolt attaching the electric buckle

to the driver seat reclining adjuster.
(g) Remove the electric buckle assy.
(h) Pull out the electric buckle wire harness through the
aperture between cushion pad and reclining adjuster.
CAUTION
connector.
(i) Loosen 2 clasps of backrest cover.
(j) Loosen 4 clasps of cushion pad cover.
(k) Using an allen wrench (key), loosen 4 bolts.

(l) Remove the cushion pad.
84
(m) Press the lock button and hold it.
84
(n) Pull out the headrest.
(o) Unzipper 2 zips.
(p) Using an allen wrench (key), loosen 8 bolts.

CAUTION
Do not damage the expanding foam.
(q) Remove 5 steel wire loops.

NOTE
Discard the removed steel wire loops.
(r) Remove the backrest.
8. DISASSEMBLE ASSISTANT DRIVER SEAT ASSY.

NOTE
• Disassemble the assistant driver seat assy by the same procedures as the driver seat assy.
• Remove the buckle assy in step (g).
• Skip step (h).
9. REASSEMBLE DRIVER SEAT ASSY.
CAUTION
Do not move the tracks when performing operation below to prevent malposition.
(a) Position the backrest properly.
NOTE
Wrap up the reclining adjuster connecting column with backrest cover.
(b) Install 5 steel wire loops.

NOTE
Be sure to replace with new loops.
(c) Using an allen wrench (key), tighten 8 bolts.

CAUTION
Do not damage the expanding foam.
(d) Zipper 2 zips.
84
(e) Press the lock button and hold it.
84
(f) Insert the headrest.
(g) Position the cushion pad properly.
(h) Using an allen wrench (key), tighten 4 bolts.

(i) Install 4 clasps of cushion pad cover.
(j) Install 2 clasps of backrest cover.

NOTE
Hide the zip into the backrest cover.
(k) Put the electric buckle wire harness connector through

the aperture between cushion pad and reclining adjuster.
CAUTION
connector.
(l) Position the electric buckle assy properly.
(m) Tighten the bolt.

(n) Install the reclining adjuster trim cover electric buckle

NOTE
• Push the trim cover inward to align the slots. 84
84
(o) Tighten the screw.
(p) Install the reclining adjuster trim cover handle side by the
sequence shown in the illustration.
NOTE
• Move the trim cover backward.
• Push the trim cover inward to align the slots.
(q) Tighten the screw.

(r) Install the reclining adjuster handle cover.
10. REASSEMBLE ASSISTANT DRIVER SEAT ASSY.

NOTE
• Reassemble the assistant driver seat assy by the same procedures as the driver seat assy.
• Position the buckle assy properly in step (k).
• Skip step (j).
11. INSTALL DRIVER SEAT BASE WELDING ASSY.

(a) Position the driver seat base welding assy properly.
(b) Pull the fuel filling door handle out of the driver seat base
welding assy through the hole.
(c) Tighten the nut.


84
(e) Position the driver seat base trim properly.
84
(f) Install 4 clips.

NOTE
Be sure to replace with new clips.
12. INSTALL ASSISTANT DRIVER SEAT BASE WELDING ASSY.

NOTE
• Install the assistant driver seat base welding assy by the same procedures as the driver seat
base welding assy.
• Skip step (b) and (c).
13. INSTALL DRIVER SEAT ASSY.
(a) Position the driver seat assy which is turned over behind the base welding assy.
WARNING
Care must be taken because the driver seat assy is quite heavy.
CAUTION
• Do not move the tracks to prevent malposition.
(b) Install the electric buckle wire harness connector to

mounting hole on the driver seat base welding assy.
CAUTION
NOTE
If the connector is broken, replace with a new electric
buckle assy. (Refer to “Chapter 63 seat belt - buckle assy,
replacement”)
(c) Connect the electric buckle wire harness connector.

CAUTION
Make sure there is no interference between electric buckle
wire harness and parts around.

CAUTION
• Make sure the driver seat assy is at the backmost
position.
• Help the seat assy carefully and slowly and position
it on the top of the base welding assy.
• Do not move the sliding tracks to prevent
malposition.
(e) Position the extinguisher bracket properly.
84
84
(g) Slide the driver seat assy foremost.
(h) Using an allen wrench (key), tighten 2 bolts.

14.INSTALL ASSISTANT DRIVER SEAT ASSY.
NOTE
•Install the assistant driver seat assy by the same
procedures as the driver seat assy.
•Skip step (b) and (c).
replacement”)
16. ADJUST DRIVER / ASSISTANT DRIVER SEAT ASSY. (Refer to “Chapter 84 seat - driver /
assistant driver seat, adjustment”)
SEAT - PASSENGER SEAT 84-25
PASSENGER SEAT
COMPONENTS
THE SHORT WHEELBASE VEHICLE EQUIPPED WITH INTERMEDIATE SEATS 84
(2+2+3)
84
1 Sliding Rail Trim 12 Rear Flip Seat Assy LH
2 Sliding Rail Trim End Cap 13 Flip Seat Lock Catch
3 Double Seat Sliding Rail Assy LH 14 Individual Seat Sliding Rail Assy LH
4 Bolt 15 Individual Seat Sliding Rail Assy RH
5 Spring Washer 16 Individual Seat Trim Cover
6 Flat Washer 17 Individual Seat Trim Cover Cap
7 Double Seat Sliding Rail Assy RH 18 Headrest Assy
8 Bolts 19 Flip Seat Headrest Assy
9 Front Individual Seat Assy RH 20 Flip Seat Trim Cover
10 Front Individual Seat Assy LH 21 Clip
11 Rear Flip Seat Assy RH

84-26 SEAT - PASSENGER SEAT
THE SHORT WHEELBASE VEHICLE EQUIPPED WITH INTERMEDIATE SEATS

(2+3+3)
1 Sliding Rail Trim 9 Rear Flip Seat Assy RH
2 Sliding Rail Trim End Cap 10 Rear Flip Seat Assy LH
3 Double Seat Sliding Rail Assy RH 11 Flip Seat Lock Catch
4 Bolt 12 Double Seat Sliding Rail Assy LH
5 Bolt 13 Headrest Assy
6 Spring Washer 14 Flip Seat Headrest Assy
7 Flat Washer 15 Flip Seat Trim Cover
8 Double Seat With Rumble Seat Assy 16 Clip


(2+2+2)
84
84
1 Sliding Rail Trim 10 Individual Seat Trim Cover
2 Sliding Rail Trim End Cap 11 Individual Seat Sliding Rail Assy LH No.1
3 Individual Seat Sliding Rail Assy RH No.1 12 Front Individual Seat Assy LH
4 Individual Seat Sliding Rail Assy RH No.2 13 Front Individual Seat Assy RH
5 Bolt 14 Rear Individual Seat Assy LH
6 Spring Washer 15 Rear Individual Seat Assy RH
7 Flat Washer 16 Headrest Assy
8 Individual Seat Sliding Rail Assy LH No.2 17 Bolt
9 Individual Seat Trim Cover Cap 18 Clip


(2+2+3)
1 Sliding Rail Trim 11 Headrest Assy
2 Sliding Rail Trim End Cap 12 Front Individual Seat Assy RH
3 Multiple Seat Sliding Rail Assy LH No.4 13 Front Individual Seat Assy LH
4 Bolt 14 Rear Sliding Multiple Seat Assy
5 Bolt 15 Double Seat Sliding Rail Assy RH
6 Spring Washer 16 Multiple Seat Sliding Rail Assy LH No.1
7 Flat Washer 17 Sliding Rail Trim
8 Individual Seat Sliding Rail Assy LH 18 Sliding Multiple Seat Trim Cover No.1
9 Individual Seat Trim Cover Cap 19 Clip
10 Individual Seat Trim Cover 20 Clip


(2+2+3)
84
84
1 Sliding Rail Trim 9 Double Seat Sliding Rail Assy LH
3 Double Seat Sliding Rail Assy RH 11 Rear Flip Seat Assy LH
4 Bolt 12 Rear Flip Seat Assy RH
8 Double Seat Assy 16 Clip


(2+3+3)
1 Bolt 9 Rear Flip Seat Assy LH
2 Spring Washer 10 Rear Flip Seat Assy RH
3 Flat Washer 11 Headrest Assy
4 Double Seat With Rumble Seat Assy 12 Flip Seat Headrest Assy
5 Sliding Rail Trim 13 Bolt
6 Double Seat Sliding Rail Assy LH 14 Flip Seat Trim Cover
7 Double Seat Sliding Rail Assy RH 15 Flip Seat Lock Catch
8 Sliding Rail Trim End Cap 16 Clip


(2+2+2+3)
84
84
1 Sliding Rail Trim 9 Double Seat Sliding Rail Assy LH No.1
3 Double Seat Sliding Rail Assy RH No.1 11 Rear Flip Seat Assy LH
4 Clip 12 Rear Flip Seat Assy RH
5 Bolt 13 Bolt
6 Spring Washer 14 Headrest Assy
7 Flat Washer 15 Flip Seat Headrest Assy
8 Double Seat Assy 16 Flip Seat Trim Cover


(2+3+3+3)
1 Sliding Rail Trim 9 Double Seat Sliding Rail Assy LH No.1
3 Double Seat Sliding Rail Assy RH No.1 11 Rear Flip Seat Assy LH
4 Bolt 12 Rear Flip Seat Assy RH
8 Double Seat With Rumble Seat Assy 16 Clip


(2+2+3)
84
84
1 Sliding Rail Trim 12 Rear Flip Seat Assy LH
3 Sliding Rail Assy No.2 14 Sliding Rail Assy No.3
4 Bolt 15 Sliding Rail Assy No.4
5 Spring Washer 16 Individual Seat Trim Cover Cap
6 Flat Washer 17 Bolt
7 Sliding Rail Assy No.1 18 Headrest Assy
8 Individual Seat Trim Cover 19 Flip Seat Headrest Assy
9 Front Individual Seat Assy RH 20 Flip Seat Trim Cover
10 Front Individual Seat Assy LH 21 Clip
11 Rear Flip Seat Assy RH


(2+2+2+3)
1 Double Seat With Rumble Seat Assy 9 Sliding Rail Trim End Cap
2 Rear Flip Seat Assy RH 10 Double Seat Sliding Rail Assy RH No.1
3 Rear Flip Seat Assy LH 11 Bolt
4 Flip Seat Lock Catch 12 Double Seat Sliding Rail Assy LH No.1
8 Sliding Rail Trim 16 Clip


(2+3+3+3)
84
84
1 Double Seat With Rumble Seat Assy 9 Sliding Rail Trim End Cap
2 Rear Flip Seat Assy RH 10 Double Seat Sliding Rail Assy RH No.1
3 Rear Flip Seat Assy LH 11 Bolt
4 Flip Seat Lock Catch 12 Double Seat Sliding Rail Assy LH No.1
8 Sliding Rail Trim 16 Clip

THE LONG WHEELBASE VEHICLE EQUIPPED WITH HIGH-GRADE SEATS

(2+2+2+3)
1 Sliding Rail Trim 12 Front Individual Seat Assy RH
2 Sliding Rail Trim End Cap 13 Front Individual Seat Assy LH
3 Sliding Rail Assy No.4 14 Sliding Rail Assy No.2
4 Bolt 15 Sliding Rail Assy No.1
5 Bolt 16 Double Seat Assy
6 Spring Washer 17 Rear Multiple Seat Assy
7 Flat Washer 18 Screw
8 Sliding Rail Assy No.3 19 Protecting Sleeve LH
9 Individual Seat Trim Cover Cap 20 Protecting Sleeve RH
10 Individual Seat Trim Cover 21 Rear Multiple Seat Lock Catch
11 Headrest Assy 22 Clip

DOOR LOCK
85
FRONT DOOR LOCKS ...................................................................... 85-1
COMPONENTS ........................................................................... 85-1
REPLACEMENT .......................................................................... 85-2
SLIDING DOOR LOCKS .................................................................... 85-9 85
COMPONENTS ........................................................................... 85-9
REPLACEMENT ........................................................................ 85-10
REAR HATCH LOCK ....................................................................... 85-17
COMPONENTS ......................................................................... 85-17 85
REPLACEMENT ........................................................................ 85-18
ENGINE HOOD LOCK ..................................................................... 85-23
COMPONENTS ......................................................................... 85-23
REPLACEMENT ........................................................................ 85-24 85
DOOR LOCKS - FRONT DOOR LOCKS 85-1
FRONT DOOR LOCKS

DOOR LOCKS
COMPONENTS
85
85
1 Front Door Lock Assy LH 2 Front Door Lock Assy RH

85-2 DOOR LOCKS - FRONT DOOR LOCKS
REPLACEMENT
NOTE
1. TURN IGNITION SWITCH OFF.

NOTE
• When disconnecting or connecting the battery
cables, please first turn off the ignition switch and
lighting switch and completely loosen the cable nut.
Do not pry up the cable when peforming these
operation.
• For the vehicle equipped with the power door locks,
before disconnecting the battery negative cable, do
not leave the key in the vehicle to avoid the door
being locked.
3. REMOVE FRONT DOOR CONTROLLER COVER LH.

(a) Remove 2 retaining screws of the front door conreoller
LH.
(b) Using a screwdriver, pry up the front door controller
cover.
(c) Disconnect 2 connectors.
4. REMOVE FRONT DOOR LOCK INNER HANDLE

ASSY LH.
(a) Remove the retaining screw.
(b) Remove 2 door lock connecting rods, then remove front

door inner handle LH.
85

LH.
(a) Using a screwdriver, pry out the front door inner triangle
plate LH.
85
(b) Using a screwdriver, pry out the front door inner guard
plate assy LH.
6. REMOVE FRONT DOOR LOCK LH.

(a) Remove 2 screws and 1 bolt and remove the handle
bracket.
(b) Remove the front door water-proof film.

(c) Disconnect the front door lock actuator LH connector.
(d) Disconnect the front door lock connecting rods from the
front door lock body LH.
NOTE
Do not damage the connecting rods plastic clamp.
(e) Remove 3 retaining screws from the front door actuator

LH.
(f) Remove the front door actuator LH.
7. INSPECT FRONT DOOR ACTUATOR ASSY LH. (Refer to “Chapter 04 diagnostics - power door
locks”)
8. REMOVE FRONT DOOR OUTER HANDLE LH.

(a) Disconnect the front door lock connecting rods from the
front door outer handle LH.
(b) Remove 2 retaing screws from the front door outer

handle LH.
(c) Remove the front door outer handle LH.
NOTE 85
Do not damage the connecting rods plastic clamp.
9. INSTALL FRONT DOOR OUTER HANDLE LH.

(a) Position the front door outer handle LH properly.
(b) Tighten 2 retaing screws to the front door outer handle
LH.
85
(c) Connect the front door lock connecting rods to the front
door outer handle LH.
10. INSTALL FRONT DOOR LOCK BODY LH.

(a) Position the front door lock body LH properly.
(b) Tighten 3 retaining screws to the front door actuator LH.
(c) Connect the front door lock connecting rods to the front
door lock body LH.
(d) Connect the front door lock actuator LH connector.
(e) Install the front door water-proof film.
(f) Position the handle bracket properly and tighten 2

screws and 1 bolt .
Torque: 7 ~ 10 N·m

LH.
(a) Position the front door inner guard plate assy LH properly
and slap it by hand until all clips lock into position.
NOTE
Must use the new clips when installing the guard plate.
(b) Position the front door inner triangle plate LH properly

and slap it by hand until all clips lock into position.
NOTE
Must use the new clips when installing the triangle plate. 85
12. INSTALL FRONT DOOR LOCK INNER HANDLE ASSY

LH.
(a) Install 2 door lock connecting rods, then install front door
inner handle LH.
85
(b) Tighten the retaining screw.
13. INSTALL FRONT DOOR CONTROLLER COVER LH.

(b) Position the front door controller cover properly.

(c) Tighten 2 retaining screws of the front door conreoller
LH.

15. RESET AUDIO SYSTEM.
16. INSPECT FRONT DOOR LOCK/UNLOCK WITH KEY.
NOTE
• For the vehicle equipped with the power door locks, before disconnecting the battery negative
cable, do not leave the key in the vehicle to avoid the door being locked.
• For the vehicle equipped with the power door locks, when inspecting front door LH lock/unlock,
the front door lock RH should be acted simultaneously.
DOOR LOCKS - SLIDING DOOR LOCKS 85-9
SLIDING DOOR LOCKS

COMPONENTS
85
85
1 Sliding Door Lock Assy LH 2 Sliding Door Lock Assy RH

85-10 DOOR LOCKS - SLIDING DOOR LOCKS
REPLACEMENT
NOTE
Remove the LH side by the same procedures as the RH side.

NOTE
operation.
being locked.
3. REMOVE SLIDING DOOR LOWER INNER GUARD

BOARD ASSY RH.
(a) Using a screwdriver, remove 2 sliding door inner handle
RH bolt covers.
(b) Remove 2 sliding door inner handle RH retaining bolts.

(c) Disconnect the connecting rods from the inner handle

RH.
(d) Remove the sliding door inner handle RH.
85
85
(e) Remove the sliding door limit stop assy RH retaining
screw.
(f) Remove the sliding door limit stop assy RH.
(g) Remove the sliding door lower inner guard board assy
RH.
(h) Remove the water-proof film.

4. REMOVE SLIDING DOOR LOCK ACTUATOR RH.

(a) Disconnect the sliding door lock actuator RH connector.
(b) Disconnect the connecting rods from the sliding door

lock actuator RH.
(c) Remove 4 retaining bolts from the sliding door lock

actuator RH.
(d) Remove the sliding door lock actuator RH.
5. INSPECT SLIDING DOOR LOCK ACTUATOR RH. (Refer to “Chapter 04 diagnostics - power door
locks”)
6. REMOVE SLIDING DOOR LOCK BODY RH.

(a) Disconnect the connecting rods from the sliding door
lock body RH.
(b) Remove 3 retaining bolts from the sliding door lock body
RH.
(c) Remove the sliding door lock body RH.
7. INSTALL SLIDING DOOR LOCK BODY RH.

(a) Position the sliding door lock body RH properly.
(b) Tighten 3 retaining bolts to the sliding door lock body RH.
(c) Connect the connecting rods to the sliding door lock 85
body RH.
8. INSTALL SLIDING DOOR LOCK ACTUATOR RH.

(a) Position the sliding door lock actuator RH porperly.
(b) Tighten 4 retaining bolts to the sliding door lock actuator
RH.
85
(c) Connect the sliding door lock actuator RH connector.
(d) Connect the connecting rods to the sliding door lock

actuator RH.
9. INSTALL SLIDING DOOR LOWER INNER GUARD

BOARD ASSY RH.
(a) Install the water-proof film.
(b) Install the sliding door lower inner guard board assy RH.
(c) Position the sliding door limit stop assy RH properly.

(d) Tighten the sliding door limit stop assy RH retaining
screw.
(e) Connect the connecting rods to the inner handle RH.

(f) Tighten 2 sliding door inner handle retaining bolts.
85
85
(g) Install 2 sliding door inner handle bolt covers.

12. INSPECT SLIDING DOOR LOCK/UNLOCK WITH KEY.
NOTE
• For the vehicle equipped with the power door locks, before disconnecting the battery negative
cable, do not leave the key in the vehicle to avoid the door being locked.
• For the vehicle equipped with the power door locks, when inspecting sliding door LH lock/
unlock, the sliding door lock RH should be acted simultaneously.
85-16 DOOR LOCKS - REAR HATCH LOCK
REAR HATCH LOCK

COMPONENTS
1 Rear Hatch Door Lock Assy

DOOR LOCKS - REAR HATCH LOCK 85-17
REPLACEMENT

NOTE
operation.
being locked.
3. REMOVE REAR HATCH LOWER INNER GUARD 85

BOARD.
(a) Using a screwdriver, remove 2 rear hatch handle screw
covers.
(b) Remove 2 rear hatch handle retaining screws.

(c) Remove the rear hatch handle.
(d) Remove the rear hatch lower inner guard board.
4. REMOVE REAR HATCH LOCK ACTUATOR.

(a) Disconnect the rear hatch lock actuator connector.
(b) Disconnect the connecting rods from the rear hatch lock
actuator.
(c) Remove 3 retaining bolts from the rear hatch lock

actuator.
(d) Remove the rear hatch lock actuator.
5. INSPECT REAR HATCH LOCK ACTUATOR. (Refer to “Chapter 04 diagnostics - power door
locks”)
6. REMOVE REAR HATCH LOCK BODY.

(a) Disconnect the connecting rod from the rear hatch lock
body.
(b) Remove 3 retaining bolts from the rear hatch lock body. 85
(c) Remove the rear hatch lock body.
85
7. INSTALL REAR HATCH LOCK BODY.
(a) Position the rear hatch lock body properly.
(b) Connect the connecting rod to the rear hatch lock body.
(c) Tighten 3 retaining bolts to the rear hatch lock body.
Torque: 7.5 ~ 10 N·m
8. INSTALL REAR HATCH LOCK ACTUATOR.

(a) Position the rear hatch lock actuator properly.
(b) Tighten 3 retaining bolts to the rear hatch lock actuator.
(c) Connect the connecting rods to the rear hatch lock

actuator.
(d) Connect the rear hatch lock actuator connector.
9. INSTALL REAR HATCH LOWER INNER GUARD

BOARD.
(a) Position the rear hatch lower inner guard board properly.
(b) Position the rear hatch handle properly.

(c) Tighten 2 rear hatch handle retaining screws.
(d) Install 2 rear hatch handle screw covers.


12. INSPECT REAR HATCH LOCK/UNLOCK WITH KEY.
85
NOTE
For the vehicle equipped with the power door locks, before disconnecting the battery negative cable,
do not leave the key in the vehicle to avoid the door being locked.
85
85-22 DOOR LOCKS - ENGINE HOOD LOCK
ENGINE HOOD LOCK

COMPONENTS
1 Engine Hood Lock Assy

DOOR LOCKS - ENGINE HOOD LOCK 85-23
REPLACEMENT
1. OPEN ENGING HOOD.
2. REMOVE ENGINE HOOD LOCK ASSY. 85

(a) Remove 3 retaining bolts from the engine hood lock.
(b) Remove the engine hood lock.
(c) Disconnect the engine hood lock cable.
85
3. INSTALL ENGINE HOOD LOCK ASSY.

(a) Connect the engine hood lock cable.
(b) Position the engine hood lock properly.

(c) Tighten 3 retaining bolts to the engine hood lock.
MEMO
SLIDING ROOF
86
SLIDING ROOF ASSY ....................................................................... 86-1
OVERHAUL ................................................................................. 86-2
86
86
86
SLIDING ROOF - SLIDING ROOF ASSY 86-1
SLIDING ROOF ASSY

SLIDING ROOF

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the 86
likely cause of the problem. Check each part in the order shown. If necessary, repair or replace these
parts.
Symptom Suspect Reference
1. Sliding rail (Insufficient lubrication) Chapter 86 sliding roof - sliding roof assy, overhaul
2. Sliding rail (Dusty) Chapter 86 sliding roof - sliding roof assy, overhaul
Abnormal
working
3. Sliding roof control switch (Failure) Chapter 86 sliding roof - sliding roof assy, overhaul
4. Sliding roof control switch (Damage) Chapter 86 sliding roof - sliding roof assy, overhaul
1. Drain hose (Obstructed) Chapter 86 sliding roof - sliding roof assy, overhaul
2. Drain hose (Damage) Chapter 86 sliding roof - sliding roof assy, overhaul
86
3. Sliding roof weatherstrip (Aging) Chapter 86 sliding roof - sliding roof assy, overhaul
Water
leakage 4. Sliding roof weatherstrip (Improper Chapter 86 sliding roof - sliding roof assy, overhaul
installation)
5. Sliding roof assy (Improper installation) Chapter 86 sliding roof - sliding roof assy, overhaul
6. Sliding roof assy (Maladjusted) Chapter 86 sliding roof - sliding roof assy, overhaul
86-2 SLIDING ROOF - SLIDING ROOF ASSY
OVERHAUL
2. REMOVE SLIDING ROOF CONTROL SWITCH.

(a) Remove the sliding roof control switch.
(b) Disconnect the connector, remove the sliding roof control

switch.
3. REMOVE SLIDING ROOF WEATHERSTRIP.
4. REMOVE ROOF GUARD BOARD. (Refer to "Chapter 88 exterior and interior trim - roof guard
board, replacement")
5. REMOVE SLIDING ROOF CONTROL MOTOR.

(a) Remove the connector of the sliding roof control motor
from the sliding roof housing.
(b) Remove 3 bolts and sliding roof control motor.
86
6. REMOVE SLIDING ROOF ASSY.

(a) Remove the rear evaporator assy. (Refer to “Chapter 61 heater and air conditioning - rear evaporator
assy, replacement)
(b) Disconnect 2 front drain hoses from the sliding roof

housing.
86
(c) Disconnect 2 rear drain hoses from the sliding roof

housing.
(d) Remove the 10 nuts and the sliding roof assy.
7. INSPECT SLIDING RAIL. CLEAN UP AND LUBRICATE THE SLIDING ROOF RAIL IF NECESSARY.
8. INSPECT SLIDING ROOF CONTROL MOTOR.
(a) Connect the battery (+) to terminal 4 of the sliding roof control motor, the battery (-) to terminal 1 of the
sliding roof control motor. And then check that the sliding roof control motor operates as “close”. If it
isn’t operating smoothly, replace the sliding roof control motor with a new part.
(b) Connect the battery (+) to terminal 1 of the sliding roof switch assy, the battery (-) to terminal 4 of the
sliding roof control motor. And then check that the sliding roof control motor operates as “open”. If it isn’t
operating smoothly, replace the sliding roof control motor with a new part.
9. INSPECT SLIDING ROOF CONTROL SWITCH.
(a) Gently press the ”open” and release the button and the sliding roof should be completely opened.
(b) Gently press the ”close” and release the button and the sliding roof should be completely closed.
(c) Press and hold down the ”open” and the sliding roof will operate untill you release the button.
(d) Press and hold down the ”close” and the sliding roof will operate untill you release the button.
10. INSTALL SLIDING ROOF ASSY.

(a) Install the sliding roof assy with 10 nuts.
(b) Connect 2 front drain hoses to the sliding roof housing.

WARNING
The drain hoses will have interest with the sealability of the
sliding roof. Inspect the drain hoses before installing them.
Replace with new drain hoses if necessary.
(c) Connect 2 rear drain hoses to the sliding roof housing.

WARNING
The drain hoses will have interest with the sealability of the
sliding roof. Inspect the drain hoses before installing them. 86
Replace with new drain hoses if necessary.
(d) Install the rear evaporator assy. (Refer to “Chapter 61

heater and air conditioning - rear evaporator assy,
86
replacement)
11. INSTALL SLIDING ROOF CONTROL MOTOR.

(a) Install the sliding roof control motor with 3 bolts.
(b) Install the connector of the sliding roof control motor to

the sliding roof housing.
12. INSTALL ROOF GUARD BOARD. (Refer to "Chapter 88 exterior and interior trim - roof guard
board, replacement")
13. INSTALL THE SLIDING ROOF WEATHERSTRIP.

WARNING
The weatherstrip will have interest with the sealability of
the sliding roof. Inspect the drain hoses before installing
them. Replace with new weatherstrip if necessary.
14. INSTALL THE SLIDING ROOF CONTROL SWITCH.

(a) Connect the connector and install the sliding roof control
switch.

16. INSPECT WHETHER SLIDING ROOF CONTROL MOTOR OPERATES SMOOTHLY OR NOT.
17. INSPECT WHETHER SLIDNG ROOF ASSY IS INSTALLED PROPERLY OR NOT.
18. INSPECT FOR WATER LEAKAGE.
(a) Inspect the sliding roof for water leakage after operating the sliding roof many times. Readjust the
position of the sliding roof assy if necessary. (Refer to “Chapter 86 sliding roof - sliding roof system,
overhaul”)
ENGINE HOOD AND DOORS
87
ENGINE HOOD .................................................................................. 87-1
ADJUSTMENT ............................................................................. 87-1
REPLACEMENT .......................................................................... 87-3
FRONT DOOR.................................................................................... 87-5 87
COMPONENTS ........................................................................... 87-5
ADJUSTMENT ............................................................................. 87-7
REPLACEMENT ........................................................................ 87-11
SLIDING DOOR................................................................................ 87-14 87
COMPONENTS ......................................................................... 87-14
ADJUSTMENT ........................................................................... 87-16
REPLACEMENT ........................................................................ 87-19
REAR HATCH .................................................................................. 87-21
COMPONENTS ......................................................................... 87-21
ADJUSTMENT ........................................................................... 87-22
REPLACEMENT ........................................................................ 87-24
87
ENGINE HOOD AND DOORS - ENGINE HOOD 87-1
ENGINE HOOD
ENGINE HOOD AND DOORS
ADJUSTMENT
1. INSPECT HOOD. 87
(a) Check that the clearance is within the specified value.
87
Clearance 4.0 +/- 1.0 mm
Flatness 0 + 0.5 / - 1.0 mm
2. ADJUST HOOD.
(a) Asjust the engine hood horizontally.
• Loosen the hood side hinge bolts.
• Move the hood to adjust the clearance within the speci-

fied value.
Specified value: 4.0 +/- 1.0 mm
• After adjusting, tighten the hood side hinge bolts.
87-2 ENGINE HOOD AND DOORS - ENGINE HOOD
(b) Adjust the hood by turning the cushions.

• Adjust the rubber cushions so as to let the hood and
fender abreast.
NOTE
Turn the rubber to let it move up and down.
(c) Adjust the engine hood lock.

• Adjust the engine hood lock position by moving the lock
so as to lock the engine hood smoothly.
• After adjusting, tighten the hood lock bolts.
ENGINE HOOD AND DOORS - ENGINE HOOD 87-3
REPLACEMENT
1. REMOVE FRONT WAHSER HOSE.
(a) Using a screwdriver, pry out the front washer hose from 87
the nozzles.
(b) Remove the front washer hose from the clamps.
2. REMOVE ENGINE HOOD.

(a) Remove 2 retaining bolts from the engine hood hinge LH.
87
(b) Remove 2 retaining bolts from the engine hood hinge

RH.
3. INSTALL ENGINE HOOD.

(a) Tighten 2 retaining bolts to the engine hood hinge LH.
87-4 ENGINE HOOD AND DOORS - ENGINE HOOD
(b) Tighten 2 retaining bolts to the engine hood hinge RH.

4. INSTALL FRONT WASHER HOSE.

(a) Install front washer hose to 2 nozzles.
(b) Fasten the front washer to the clamps.
5. ADJUST ENGINE HOOD. (Refer to “Chapter 87 engine hood and doors - engine hood,
adjustment”)
ENGINE HOOD AND DOORS - FRONT DOOR 87-5
FRONT DOOR
COMPONENTS
87
87
1 Front Door Inner Weatherstrip Assy LH Front Door Glass Rear Rail Weatherstrip
10
LH
2 Front Door Limit Seat
11 Rear Glass Guide Slot Assy LH
3 Clip
12 Handle Bracket
4 Front Door Inner Triangle Plate LH
13 Front Door Water-proof Film
5 Front Door Rubber Limit Stop
14 Front Door Glass Weatherstrip LH
6 Front Glass Guide Slot Assy LH
15 Front Door Glass Assy LH
7 Front Door Glass Inner Weather Bar LH
16 Clip
8 Front Door Controller Cover LH
17 Clip
9 Front Door Inner Guard Plate Assy LH
87-6 ENGINE HOOD AND DOORS - FRONT DOOR
1 Front Door Inner Weatherstrip Assy RH 10 Rear Glass Guide Slot Assy RH
2 Front Door Inner Triangle Plate RH 11 Front Door Rubber Limit Stop
3 Front Door Glass Weatherstrip RH 12 Front Door Water-proof Film
4 Front Door Glass Assy RH 13 Front Door Controller Cover RH
5 Front Door Glass Inner Weather Bar RH 14 Clip
6 Front Glass Guide Slot Assy RH 15 Front Door Limit Seat
7 Front Door Inner Guard Plate Assy RH 16 Clip
8 Handle Bracket 17 Clip
Front Door Glass Rear Rail Weatherstrip

9
RH
ADJUSTMENT
NOTE
Adjust the RH side by the same procedures as the LH side.
87
1. INSPECT FRONT DOOR LH.
87
Flatness 0 +/- 1.0 mm


87
87
2. ADJUST FRONT DOOR LH.

(a) Adjust the door vertically and horizontally by loosening
the body side hinge bolts.
NOTE
It is necessary to remove the fender before loosening the
body side hinge bolts.
(b) After adjusting, tighten the body hinge bolts.
(c) Adjust the door vertically and horizontally by loosening

the body side hinge bolts.
(d) After adjusting, tighten the body hinge bolts.
(e) Adjust the striker position by slightly loosening the striker

mounting screws and hitting the striker with a plastic
hammer.
(f) After adjusting, tighten the striker mounting screws.
REPLACEMENT
1. DISCONNECT FRONT DOOR CONNECTOR.
87
2. REMOVE FRONT DOOR CHECK LH.

(a) Remove 2 retaining bolts from the front door check LH.
87
3. REMOVE FRONT DOOR HINGE LH.

(a) Remove 6 retaining bolts from the front door hinge LH.
(b) Remove the front door assy.
4. REMOVE FRONT DOOR WEATHERSTRIP.

(a) Pry out the front door weatherstrip clips and then remove
the weatherstrip.
NOTE
Discard the removed clips.
5. INSTALL FRONT DOOR HINGE LH.

(a) Position the front door LH properly. After adjusting the
front door clearance, tighten 6 retaining bolts to the front
door hinge LH.
6. INSTALL FRONT DOOR CHECK LH.

(a) Position the front door check properly and tighten 2
retaining bolts.
Torque: 8.5~ 10 N·m
7. CONNECT FRONT DOOR LH CONNECTOR.
87
8. INSTALL FRONT DOOR WEATHERSTRIP LH.

(a) Position the weatherstrip properly with new clips.
NOTE
Use new parts when installing. 87
9. ADJUST FRONT DOOR LH.

(a) Refer to “Chapter 87 engine hood and doors - front door, adjustment”
10. REMOVE FRONT DOOR RH.

NOTE
87-14 ENGINE HOOD AND DOORS - SLIDING DOOR
SLIDING DOOR
COMPONENTS
ENGINE HOOD AND DOORS - SLIDING DOOR 87-15
1 Sliding Door Upper Rubber Limit Stop 21 Sliding Door Spring Clip RH
Sliding Door Upper Concave Limiting Sliding Door Middle Concave Limiting
2 22
Device Device RH
87
3 Bolt 23 Concave Lower Plastic Box
Sliding Door Limiting Device (Convex To Sliding Door Electric Concave Limiting
4 24
The Above) Device Assy RH
5 Sliding Door Upper Bracket Assy RH 25 Sliding Door Glass Weatherstrip RH
6 Bolt 26 Sliding Door Glass Assy RH
Sliding Door Upper Inner Guard Board 27 Decorative Cover

7
Assy RH
28 Sliding Door Glass Assy LH
8 Screw
29 Sliding Door Glass Weatherstrip LH
Sliding Door Middle Convex Limiting
9 Sliding Door Lower Upper Guard Board
Device Assy 30
Assy LH
Sliding Door Electric Convex Limiting
10 Sliding Door Lower Inner Guard Board
Device Assy 31
Assy LH
11 Sliding Door Limit Stop Assy 87
32 Sliding Door Spring Clip LH
12 Bolt
33 Sliding Door Lower Bracket LH
Sliding Door Limiting Device (Convex To
13 Sliding Door Lower Bracket Guide Assy
The Below) 34
LH
14 Lower Concave Limiting Device
Sliding Door Middle Slideway Bracket
35
15 Sliding Door Lower Rubber Limit Stop Assy LH
16 Sliding Door Lower Bracket RH Sliding Door Electric Concave Limiting

36
Device Assy LH
Sliding Door Lower Bracket Guide Assy
17
RH 37 Clip
18 Bolt 38 Bolt
Sliding Door Middle Slideway Bracket 39 Sliding Door Upper Bracket Assy LH
19
Assy RH
Sliding Door Lower Inner Guard Board

20
Assy RH
ADJUSTMENT
1. INSPECT SLIDING DOOR.

87
87
Flatness 3.0 +/- 1.5 mm
2. ADJUST SLIDING DOOR.

(a) Loosen the sliding door upper bracket bolts.
(b) Loosen the sliding door lower bracket bolts.

(c) Adjust the door vertically and horizontally.
(d) After adjusting, tighten the sliding door bracket bolts.
(e) Adjust the middle convex limiting device by slightly loos-

ening the middle convex limiting device mounting screws
and hitting the middle convex limiting device with a plas-
tic hammer.
(f) Adjust the lock catch by slightly loosening the lock catch
mounting bolts and hitting the lock catch with a plastic
hammer.
(g) Adjust the middle concave limiting device by slightly

loosening the middle concave limiting device mounting
bolts and hitting the middle concave limiting device with a
plastic hammer.
(h) After adjusting, tighten those bolts and screws.
REPLACEMENT
1. REMOVE SLIDING DOOR RH.
(a) Remove 2 mounting bolts from the sliding door lower 87
bracket.
(b) Remove 3 mounting bolts from the sliding door upper

bracket.
87
(c) Move forward the sliding door and separate it from the
middle rail.
(d) Remove the sliding door assy RH.
2. INSTALL SLIDING DOOR RH.

(a) Position the sliding door middle rail into the guide slot.
(b) Tighten 2 mounting bolts to lower bracket.
(c) Tighten 3 mounting bolts to upper bracket.

3. ADJUST SLIDING DOOR RH. (Refer to “Chapter 87 engine hood and doors - sliding door,
adjustment”)
4. REMOVE SLIDING DOOR LH.
NOTE
Remove the LH side by the same procedures as the RH side.
ENGINE HOOD AND DOORS - REAR HATCH 87-21
REAR HATCH
COMPONENTS
87
87
1 Rear Hatch Handle 10 Bolt
2 Rear Hatch Middle Guard Board LH 11 Rear Hatch Concave Limiting Device Assy
3 Rear Hatch Upper Guard Board Assy 12 Bolt
4 Rear Hatch Middle Guard Board RH 13 Rear Hatch Convex Limiting Device Assy
5 Rear Window Glass Assy 14 Lower Damping Block
6 Rear Hatch Lower Inner Guard Board 15 License Lamp Decoration Plate Assy
7 Rear Hatch Lower Water-proof Film 16 Hatch Bar Assy RH
8 Clip 17 Bolt
9 Hatch Bar Assy LH 18 Spoiler Assy

87-22 ENGINE HOOD AND DOORS - REAR HATCH
ADJUSTMENT
1. INSPECT REAR HATCH.
Clearance 8 +/- 2.0 mm

2. ADJUST REAR HATCH.

(a) Adjust the lock catch by slightly loosening the lock catch
mounting bolts and hitting the lock catch with a plastic
hammer. 87
(b) After adjusting, tighten the lock catch mounting bolts
(c) Loosen the rear hatch hinge mounting bolts to adjust the
rear hatch position.
(d) After adjusting, tighten the rear hatch hinge mounting
bolts
87
REPLACEMENT
1. REMOVE HIGH-MOUNTED STOP LAMP ASSY. (Refer to “Chapter 64 lighting - high-mounted
stop lamp assy, replacement”)
2. REMOVE REAR WASHER HOSE.

(a) Disconnect the rear washer hose from the 2-way joint.
3. DISCONNECT REAR HATCH CONNECTOR.
4. REMOVE HATCH BAR ASSY LH.

(a) Remove 2 upper mounting bolts from the hatch bar assy
LH.
(b) Remove 2 lower mounting bolts from the hatch bar assy
LH.
5. REMOVE HATCH BAR LH BODY.

(a) Remove the hatch bar LH body upper snap ring.
(b) Remove the hatch bar LH body lower snap ring.

(c) Remove the hatch bar LH body.
WARNING
87
• Do not disassemble it or throw it into fire.
• Using a drill, make a hole in the hatch bar to
discharge the gas inside.
6. REMOVE HATCH BAR RH.

NOTE
7. REMOVE REAR HATCH HINGE.

(a) Hold the rear hatch and remove 4 mounting bolts from
the rear hatch hinge.
87
8. INSTALL REAR HATCH.

(a) Tighten 4 mounting bolts to the rear hatch hinge.
(b) Position the hatch bar properly and tighten the upper
snap ring.
(c) Position the hatch bar properly and install the lower snap
ring.
(d) Hold the rear hatch and tighten 4 mounting bolts to hatch
bar LH and RH.
(e) Connect the rear hatch connector.
(f) Connect the rear washer hose.
9. ADJUST REAR HATCH

(a) Refer to “Chapter 87 engine hood and doors - rear hatch, adjustment”
EXTERIOR AND INTERIOR
88
FRONT GRILLE ................................................................................. 88-1
COMPONENTS ........................................................................... 88-1
REPLACEMENT .......................................................................... 88-2
FRONT BUMPER ASSY .................................................................... 88-4 88
COMPONENTS ........................................................................... 88-4
REPLACEMENT .......................................................................... 88-5
WHEEL MUDGUARD......................................................................... 88-9
REPLACEMENT .......................................................................... 88-9 88
SPOILER ASSY ............................................................................... 88-13
COMPONENTS ......................................................................... 88-13
REPLACEMENT ........................................................................ 88-14
REAR BUMPER ASSY .................................................................... 88-17
COMPONENTS ......................................................................... 88-17
REPLACEMENT ........................................................................ 88-18
SUN VISOR ASSY ........................................................................... 88-21
COMPONENTS ......................................................................... 88-21
REPLACEMENT ........................................................................ 88-22
STEP BOARD .................................................................................. 88-24
COMPONENTS ......................................................................... 88-24 88
REPLACEMENT ........................................................................ 88-25
VEHICLE DOOR INNER GUARD BOARD ...................................... 88-28
COMPONENTS ......................................................................... 88-28
REPLACEMENT ........................................................................ 88-30
SIDE WALL GUARD BOARD.......................................................... 88-37
COMPONENTS ......................................................................... 88-37
REPLACEMENT ........................................................................ 88-38
CARPET ........................................................................................... 88-47
COMPONENTS ......................................................................... 88-47
REPLACEMENT ........................................................................ 88-48
ROOF GUARD BOARD ASSY ........................................................ 88-52
COMPONENTS ......................................................................... 88-52
REPLACEMENT ........................................................................ 88-54
EXTERIOR AND INTERIOR TRIM - FRONT GRILLE 88-1
FRONT GRILLE
EXTERIOR AND INTERIOR TRIM
COMPONENTS
88
88
1 Front Grille 4 Front Bumper Assy
2 Snap Button 5 Retaining Bolt
3 Retaining Bolt 6 Washer

88-2 EXTERIOR AND INTERIOR TRIM - FRONT GRILLE
REPLACEMENT
1. OPEN ENGINE HOOD.
2. REMOVE FRONT GRILLE.

(a) Remove 2 bolts.
(b) Remove 3 clips.
(c) Remove 5 iron clips and front grille.

EXTERIOR AND INTERIOR TRIM - FRONT GRILLE 88-3
3. INSTALL FRONT GRILLE.

(a) Install 5 iron clips.
88
(b) Install 3 clips.
88
(c) Install 2 bolts.
4. CLOSE ENGINE HOOD.

88-4 EXTERIOR AND INTERIOR TRIM - FRONT BUMPER ASSY
FRONT BUMPER ASSY

COMPONENTS
1 Front Grille 4 Front Bumper Assy
2 Clip 5 Retaining Bolt
3 Retaining Bolt 6 Washer

EXTERIOR AND INTERIOR TRIM - FRONT BUMPER ASSY 88-5
REPLACEMENT
1. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior and interior - front grille, replacement”)
88
3. REMOVE FRONT BUMPER ASSY.
(a) Remove 2 bolts from front bumper assy.
(b) Remove 3 bolts of front bumper assy.
88
(c) Remove 6 bolts from front bumper assy by downside.

(d) Remove 2 bolts from front bumper assy by the wheel

side.
(e) Disconnect the connectors of front fog lamps.
(f) Remove front fog lamps. (Refer to “Chapter 64 lighting -

front fog lamp assy, replacement”)
(g) Remove front bumper assy.
4. INSTALL FRONT BUMPER ASSY.

(a) Install front fog lamps. (Refer to “Chapter 64 lighting - front fog lamp assy, replacement”)
EXTERIOR AND INTERIOR TRIM - FRONT BUMPER ASSY 88-7
(b) Connect the connectors of front fog lamps.
88
(c) Install the front bumper assy with 2 bolts by the wheel
side.
88
(d) Install 3 bolts to front bumper assy.

(e) Install 6 bolts to front bumper assy by downside.
(f) Install 2 bolts to front bumper assy.
5. INSTALL FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille,
replacement”)
EXTERIOR AND INTERIOR TRIM - WHEEL MUDGUARD 88-9
WHEEL MUDGUARD
REPLACEMENT
1. REMOVE FRONT WHEEL MUDGUARD LH. 88
(b) Remove the screw by side.
88
(c) Remove the wheel mudguard.
2. REMOVE FRONT WHEEL MUDGUARD RH.

NOTE
88-10 EXTERIOR AND INTERIOR TRIM - WHEEL MUDGUARD
3. REMOVE REAR WHEEL MUDGUARD.

(a) Remove 2 screws by front.
(b) Remove the screw by downside.
(c) Remove rear wheel mudguard LH.
4. REMOVE REAR WHEEL MUDGUARD RH.

NOTE
EXTERIOR AND INTERIOR TRIM - WHEEL MUDGUARD 88-11
5. INSTALL REAR WHEEL MUDGUARD LH.

(a) Install rear wheel mudguard LH, tighten the screw by
downside.
88
(b) Install 2 screws of rear wheel mudguard LH.
88
6. INSTALL REAR WHEEL MUDGUARD RH.

NOTE
7. INSTALL FRONT WHEEL MUDGUARD LH.

(a) Install the front wheel mudguard LH, tighter 2 screws.
88-12 EXTERIOR AND INTERIOR TRIM - WHEEL MUDGUARD
(b) Tighten screws of front wheel mudguard LH.
8. INSTALL FRONT WHEEL MUDGUARD RH.

NOTE
EXTERIOR AND INTERIOR TRIM - SPOILER ASSY 88-13
SPOILER ASSY
COMPONENTS
88
88
1 Spoiler Assy 3 Nut
2 Bolt
88-14 EXTERIOR AND INTERIOR TRIM - SPOILER ASSY
REPLACEMENT
2. REMOVE SPOILER ASSY.

(a) Remove the bolt of spoiler assy by leftside.
(b) Remove the bolt of spoiler assy by rightside.
(c) Remove the rear hatch upper guard board and nut.
EXTERIOR AND INTERIOR TRIM - SPOILER ASSY 88-15
(d) Disconnect the connector of high-mounted stop lamp.
88
(e) Remove the spoiler assy.
88
3. INSTALL SPOILER ASSY.

(a) Connect the connector of high-mounted stop lamp.
88-16 EXTERIOR AND INTERIOR TRIM - SPOILER ASSY
(b) Tighten the bolt of spoiler assy by leftside.
(c) Tighten the bolt of spoiler assy by rightside.
(d) Install the nut and rear hatch upper guard board.

EXTERIOR AND INTERIOR TRIM - REAR BUMPER ASSY 88-17
REAR BUMPER ASSY

COMPONENTS
88
88
1 Clip 3 Bolt
2 Washer 4 Rear Bumper Assy

88-18 EXTERIOR AND INTERIOR TRIM - REAR BUMPER ASSY
REPLACEMENT
2. REMOVE REAR BUMPER ASSY.
(a) Remove the rear carpet rear press strip. (Refer to “Chapter 88 exterior and interior - rear bumper assy,
replacement”)
(b) Remove rear wheel mudguards. (Refer to “Chapter 88 exterior and interior - wheel mudguard,
replacement”)
(c) Remove 6 bolts from rear bumper assy.
(d) Remove the bolt from rear bumper assy near rear wheel
LH side.
(e) Remove the bolt from rear bumper assy near rear wheel
RH side.
EXTERIOR AND INTERIOR TRIM - REAR BUMPER ASSY 88-19
(f) Disconnect the connector of rear fog lamp assy.
88
(g) Remove the rear bumper assy.
3. INSTALL REAR BUMPER ASSY.

(a) Connect the connector of rear lamp. 88
(b) Install the rear bumper assy, tighten 6 bolts of rear

bumper assy.
88-20 EXTERIOR AND INTERIOR TRIM - REAR BUMPER ASSY
(c) Install 2 bolts of rear bumper assy near rear wheel LH

side.
(d) Install 2 bolts of rear bumper assy near rear wheel RH

side.
(e) Install rear wheel mudguards. (Refer to “Chapter 88

exterior and interior - wheel mudguard, replacement”)
(f) Install the rear carpet rear press strip. (Refer to “Chapter
88 exterior and interior - rear bumper assy, replacement”)
EXTERIOR AND INTERIOR TRIM - SUN VISOR ASSY 88-21
SUN VISOR ASSY

COMPONENTS
88
88
1 Bolt 3 Hook
2 Sun Visor Assy RH 4 Sun Visor Assy LH

88-22 EXTERIOR AND INTERIOR TRIM - SUN VISOR ASSY
REPLACEMENT
1. REMOVE SUN VISOR ASSY LH.
(a) Remove 2 bolts of sun visor assy.
(b) Remove the bolt of the hook.
(c) Remove sun visor assy.
2. REMOVE SUN VISOR ASSY RH.

NOTE
3. INSTALL SUN VISOR ASSY LH.

(a) Install the sun visor assy LH, tighten the bolt of the hook.
EXTERIOR AND INTERIOR TRIM - SUN VISOR ASSY 88-23
(b) Install 2 bolts of sun visor assy.
88
4. INSTALL SUN VISOR ASSY RH.

NOTE
88
88-24 EXTERIOR AND INTERIOR TRIM - STEP BOARD
STEP BOARD
COMPONENTS
1 Snap Button 4 Retaining Screw
2 Front Step Board Cover Assy RH 5 Sliding Door Step Board Cover Assy RH
3 Clip 6 Front Step Board Cover Assy LH

EXTERIOR AND INTERIOR TRIM - STEP BOARD 88-25
REPLACEMENT
1. REMOVE FRONT STEP BOARD COVER ASSY LH.
(a) Use a screwdriver to remove 3 covers.
88
NOTE
Be carful not to damage the step board cover assy. Tape the
(b) Remove 3 screws of step board cover assy LH.
88
(c) Disengage 4 clips, remove the step board cover assy LH.
88-26 EXTERIOR AND INTERIOR TRIM - STEP BOARD
2. REMOVE FRONT STEP BOARD COVER ASSY RH.

NOTE
3. REMOVE SLIDING DOOR STEP BOARD COVER ASSY RH.
(a) Disconnect battery negative cable.
(b) Disengage 10 clips.
(c) Remove the step lamp assy. (Refer to “Chapter 64

lighting - step lamp assy, replacement”)
(d) Remove the sliding door step board cover RH.
4. INSTALL SLIDING DOOR STEP BOARD COVER ASSY RH.

(a) Connect the connector of the step lamp, install the step lamp to the sliding door step board cover assy.
(Refer to “Chapter 64 lighting - step lamp assy, replacement”)
(b) Install 10 clips and sliding door step board cover assy.
(c) Connect battery negative cable.

EXTERIOR AND INTERIOR TRIM - STEP BOARD 88-27
5. INSTALL FRONT STEP BOARD COVER ASSY LH.

(a) Install 4 clips and the step board cover assy LH.
88
(b) Install 3 screws of step board cover assy LH.
88
(c) Install 3 screws of step board cover assy LH.
6. INSTALL FRONT STEP BOARD COVER ASSY RH.

NOTE
88-28 EXTERIOR AND INTERIOR TRIM - VEHICLE DOOR INNER GUARD BOARD
VEHICLE DOOR INNER GUARD BOARD

COMPONENTS
EXTERIOR AND INTERIOR TRIM - VEHICLE DOOR INNER GUARD BOARD 88-29
1 Sliding Door RH 9 Rear Door Plank
2 Sliding Door Upper Inner Guard Board Rh 10 License Plate Lamp Decoration Plate
3 Sliding Door Lower Inner Guard Board RH 11 Front Door Inner Triangle Plate LH 88
4 Rear Door Mid-left Guard Board 12 Front Door Assy
5 Rear Door Upper Guard Board 13 Front Door Controller Cover Plate LH
6 Rear Door Mid-right Guard Board 14 Front Door Inner Guard Plate Assy LH
7 Rear Door Handle 15 Clip
8 Rear Door Lower Inner Guard Board
88
REPLACEMENT

LH.
(b) Use a screwdriver to remove the front door controller
cover LH.
NOTE
Be carful not to damage the front door controller cover LH.
Tape the screwdriver tip before using it.
(c) Disconnect the connector of the front door controller

cover LH.
(d) Remove the screw of front door lock inner handle assy
LH.
(e) Remove 2 door lock connecting rods, then remove front

inner handle LH.
(f) Remove the front door inner triangle plate LH.
88
(g) Disengage 13 clips, remove the front door inner guard

plate assy LH.
88
3. REMOVE FRONT DOOR INNER GUARD PLATE ASSY RH.

NOTE
4. REMOVE THE SLIDING DOOR UPPER INNER

GUARD BOARD RH.
(a) Disengage 2 clips and remove sliding door upper inner
guard board RH.
5. REMOVE SLIDING DOOR LOWER INNER GUARD BOARD RH.

(a) Remove the sliding door limit. (Refer to “Chapter 85 door lock - sliding door lock, replacement”)
(b) Remove the sliding door inner handle assy. (Refer to “Chapter 85 door lock - sliding door lock,
replacement”)
(c) Disengage 13 clips and remove the sliding door lower

inner guard board RH.
6. REMOVE REAR HATCH LOWER INNER GUARD

BOARD.
(a) Disengage 4 clips and remove the rear hatch upper inner
guard board.
(b) Disengage 2 clips and remove rear door mid-left and

mid-right guard board.
(c) Use a screwdriver to remove the bolt cover of rear hatch

handle.
NOTE
Be carful not to damage the rear hatch lower inner guard
board. Tape the screwdriver tip before using it.
(d) Remove 2 blots of rear hatch handle, remove the rear

hatch handle.
88
(e) Disengage 17 clips, remove the rear hatch lower inner

guard board.
88
7. INSTALL REAR HATCH LOWER INNER GUARD

BOARD.
(a) Install the rear hatch lower inner guard board with 17
clips.
(b) Install the rear hatch handle with 2 bolts.

Torque: 7.5 ~ 10 N•m
(c) Install the bolt cover of rear hatch handle.
(d) Install rear door mid-left and mid-right guard board with 2
clips.
(e) Install the rear hatch upper inner guard board with 4
clips.
8. INSTALL SLIDING DOOR LOWER INNER GUARD

BOARD RH.
(a) Install the sliding door lower inner guard board RH with
13 clips.
(b) Install the sliding door inner handle assy. (Refer to

“Chapter 85 door lock - sliding door lock, replacement”)
(c) Install the sliding door limit. (Refer to “Chapter 85 door
lock - sliding door lock, replacement”)
9. INSTALL THE SLIDING DOOR UPPER INNER GUARD

BOARD RH.
(a) Install sliding door upper inner guard board RH with 2
clips. 88

LH.
(a) Install the front door inner guard plate assy LH with 13
clips.
88
(b) Install the front door inner triangle plate LH.

(c) Install 2 door lock connecting rods, then install front inner
handle LH.
(d) Install the door lock inner handle assy LH with the screw.
(e) Connect the connector of the front door controller cover

LH.
(f) Install 2 screws.

(g) Install the front door controller cover LH.

12. INSTALL FRONT DOOR INNER GUARD PLATE ASSY RH.
NOTE
EXTERIOR AND INTERIOR TRIM - SIDE WALL GUARD BOARD 88-37
SIDE WALL GUARD BOARD

COMPONENTS
88
88
1 Side Wall Welded Assy 6 Side Wall Front Lower Guard Board LH
2 A Pillar Upper Inner Guard Board 7 Passenger Handle
3 Pillar-A Handle 8 D Pillar Upper Inner Guard Board
4 B Pillar Upper Inner Guard Board 9 Side Wall Rear Lower Guard Board LH
5 C Pillar Upper Inner Guard Board

88-38 EXTERIOR AND INTERIOR TRIM - SIDE WALL GUARD BOARD
REPLACEMENT
2. REMOVE A PILLAR UPPER INNER GUARD BOARD

LH.
(a) Use a screwdriver to remove the bolt covers of pillar-A
handle.
NOTE
Be carful not to damage the pillar-A handle. Tape the
(b) Remove 2 bolts and pillar-A handle.
(c) Remove the bolt covers of passenger handle.

(d) Remove 2 bolts and passenger handle.
88
(e) Disengage 3 clips and remove A pillar upper inner guard

board.
88
3. REMOVE A PILLAR UPPER INNER GUARD BOARD RH.

NOTE
4. REMOVE B PILLAR UPPER INNER GUARD BOARD LH.

(a) Remove driver seat belt anchor adjuster assy. (Refer to “Chapter 63 seat belt - anchor adjuster assy,
replacement”)
(b) Disengage 3 clips. Lift and remove the B pillar upper and
inner guard board.
5. REMOVE B PILLAR UPPER INNER GUARD BOARD RH.

NOTE
6. REMOVE SIDE WALL FRONT LOWER GUARD BOARD LH.
(a) Remove driver seat meshbelt with retractor assy. (Refer to “Chapter 63 seat belt - anchor adjuster assy,
replacement”)
(b) Use a screwdriver to remove the rear heater controller.

NOTE
Be careful not to damage the side wall front lower guard
board LH. Tape the screwdriver tip before using it.
(c) Disconnect the connector of rear heater controller.

(d) Disengage 12 clips. Lift and remove the side wall front
lower guard board LH.
88
7. REMOVE SIDE WALL FRONT LOWER GUARD BOARD RH.

NOTE
8. REMOVE SIDE WALL REAR LOWER GUARD BOARD

LH.
(a) Disengage 11 clips. Lift and remove the side wall rear 88
9. REMOVE SIDE WALL REAR LOWER GUARD BOARD RH.

NOTE
10. REMOVE C AND D PILLAR UPPER INNER GUARD

BOARD LH.
(a) Disengage 2 clips. Lift and remove C pillar upper and
inner guard board.
(b) Disengage 5 clips. Lift and remove D pillar upper and

inner guard board.
11. REMOVE C AND D PILLAR UPPER INNER GUARD BOARD RH.

NOTE
12. INSTALL C AND D PILLAR UPPER INNER GUARD

BOARD LH.
(a) Install C pillar upper and inner guard board with 2 clips.
(b) Install D pillar upper and inner guard board with 2 clips.
88
13. INSTALL C AND D PILLAR UPPER INNER GUARD BOARD RH.

NOTE
14. INSTALL SIDE WALL REAR LOWER GUARD BOARD

LH.
(a) Install the side wall rear lower guard board LH with 11 88
clips.
15. INSTALL SIDE WALL REAR LOWER GUARD BOARD RH.

NOTE
16. INSTALL SIDE WALL FRONT LOWER GUARD

BOARD LH.
(a) Connect the connector of rear heater controller.
(b) Install the rear heater controller to the side wall front
(c) Install the side wall front lower guard board LH with 12
clips.
(d) Install driver seat meshbelt with retractor assy. (Refer to

“Chapter 63 seat belt - anchor adjuster assy,
replacement”)
17. INSTALL SIDE WALL FRONT LOWER GUARD BOARD RH.

NOTE
18. INSTAL B PILLAR UPPER INNER GUARD BOARD

LH.
(a) Install the B pillar upper and inner guard board with 3
clips. 88
(b) Install driver seat belt anchor adjuster assy. (Refer to

“Chapter 63 seat belt - anchor adjuster assy,
replacement”)
19. INSTALL A PILLAR UPPER INNER GUARD BOARD

LH.
(a) Install A pillar upper inner guard board.
88
(b) Install passenger handle with 2 bolts.

(c) Install the bolt covers of passenger handle.
(d) Install 2 bolts and pillar-A handle.
(e) Install the bolt covers of pillar-A handle.
20. INSTALL A PILLAR UPPER INNER GUARD BOARD RH.

NOTE
EXTERIOR AND INTERIOR TRIM - CARPET 88-47
CARPET
COMPONENTS
88
88
1 Front Carpet Assy 7 Wheel House Carpet Assy LH
2 Rear Carpet Assy 8 Rear Carpet Rear Cushion RH
3 Wheel House Carpet Assy RH 9 Rear Carpet Rear Cushion LH
4 Rear Carpet Rear Press Strip 10 Rear Carpet Front Cushion LH
5 Retaining Screw 11 Rear Carpet Front Cushion RH
6 Flush Plastic Nut

88-48 EXTERIOR AND INTERIOR TRIM - CARPET
REPLACEMENT
1. REMOVE FRONT CARPET ASSY.
(a) Remove driver assistant driver seat. (Refer to “Chapter 63 seat - driver / assistant driver seat, removal
& installation and disassembly & reassembly)
(b) Remove middle platform body. (Refer to “Chapter 83 instrument panel - middle platform, replacement”)
(c) Remove the front carpet assy.
2. REMOVE REAR CARPET ASSY.

(a) Remove passenger seat. (Refer to “Chapter 84 seat - passenger seat, components”)
(b) Remove side wall lower guard board LH. (Refer to “Chapter 88 exterior and interior trim - side wall
(c) Remove side wall lower guard board RH. (Refer to “Chapter 88 exterior and interior trim - side wall
(d) Remove 5 screws and rear carpet rear press strip.

(e) Remove the rear carpet assy.
88
(f) Remove all 4 cushions.
88
(g) Remove wheel house carpet assy LH.
(h) Remove wheel house carpet assy RH.

NOTE
Remove the RH side by the same procedures as the LH
side.
88-50 EXTERIOR AND INTERIOR TRIM - CARPET
3. INSTALL REAR CARPET ASSY.

(a) Install wheel house carpet assy LH.
(b) Install wheel house carpet assy RH.

NOTE
(c) Install all 4 cushions.
(d) Install the rear carpet assy.

(e) Tighten 5 screws, install the rear carpet rear press strip.
(f) Install side wall lower guard board LH. (Refer to “Chapter
88 exterior and interior trim - side wall guard board,
replacement”) 88
(g) Install side wall lower guard board RH. (Refer to
(h) Install passenger seat. (Refer to “Chapter 84 seat -
passenger seat, components”)
4. INSTALL FRONT CARPET ASSY.

(a) Install the front carpet assy.
(b) Install middle platform body. (Refor to “Chapter 83
instrument panel - middle platform, replacement”)
(c) Install driver assistant driver seat. (Refer to “Chapter 63
seat - driver / assistant driver seat, removal & installation
and disassembly & reassembly)
88
88-52 EXTERIOR AND INTERIOR TRIM - ROOF GUARD BOARD ASSY
ROOF GUARD BOARD ASSY

COMPONENTS
W/O SLIDING ROOF
1 Air-vent Grill (w/switch) Assy RH 4 Intake Grill RH
2 Clip 5 Intake Grill LH
3 Roof Guard Board Assy 6 Air-vent Grill (w/switch) Assy LH

EXTERIOR AND INTERIOR TRIM - ROOF GUARD BOARD ASSY 88-53
WITH SLIDING ROOF
88
88
1 Clamp 6 Air-vent Grill (w/switch) Assy RH
2 Drain Hose 7 Intake Grill RH
3 Sliding Roof Assy 8 Intake Grill LH
4 Sliding Roof Weatherstrip 9 Air-Vent Grill (w/switch) Assy LH
5 Clip 10 Roof Guard Board Assy

REPLACEMENT
2. REMOVE ROOF GUARD BOARD ASSY.
(a) Remove a pillar upper inner guard board LH. (Refer to “Chapter 88 exterior and interior trim - side wall
(b) Remove 6 passenger handles. (Refer to “Chapter 88 enterior and interior trim - roof guard board assy,
replacement”)
(c) Remove front indoor lamp assy. (Refer to “Chapte 64 lighting - front indoor lamp assy, replacement”)
(d) Remove rear view mirror. (Refer to “Chapter 82 windshield - rear view mirror, replacement”)
(e) Remove the intake grille LH.
(f) Remove the intake grille RH.
(g) Remove the vent grille with switch assy LH.
(h) Disconnect the connectors.

(i) Remove the vent grille with switch assy RH.
88
(j) Disconnect the connectors.
(k) Remove rear indoor lamp assy. (Refer to “Chapter 64

lighting - rear indoor lamp assy, replacement”) 88
(l) Disengage 8 clips and remove the roof guard board assy.
3. INSTALL ROOF GUARD BOARD ASSY.

(a) Install 8 clips and the roof guard board assy.
(b) Install rear indoor lamp assy. (Refer to “Chapter 64

lighting - rear indoor lamp assy, replacement”)
(c) Connect the connectors.
(d) Install the vent grille with switch assy RH.
(e) Connect the connectors.

(f) Install the vent grille w/switch assy LH.
88
(g) Install the intake grille RH.
(h) Install the intake grille LH.

88
(i) Install rear view mirror. (Refer to “Chapter 82 windshield -

rear view mirror, replacement”)
(j) Install front indoor lamp assy. (Refer to “Chapter 64
lighting - front indoor lamp assy, replacement”)
(k) Install 6 passenger handles. (Refer to “Chapter 88
enterior and interior trim - roof guard board assy,
replacement”)
(l) Install a pillar upper inner guard board LH. (Refer to
“Chapter 88 exterior and interior - side wall guard board)

VEHICLE CONTROL SYSTEM
91
IGNITION SWITCH ASSY .................................................................. 91-1
INSPECTION ............................................................................... 91-1
REMOVAL & INSTALLATION AND
DISASSEMBLY & REASSEMBLY ............................................... 91-2 91
91
91
VEHICLE CONTROL SYSTEM - IGNITION SWITCH ASSY 91-1
IGNITION SWITCH ASSY

VEHICLE CONTROL SYSTEM
INSPECTION
91
1. INSPECT IGNITION SWITCH ASSY.
Standard:
Switch position Terminal Specified condition

LOCK AM1 - ACC - IG1 - ST1 - AM2 - IG2 - ST2 ≥ 1 MΩ
ACC AM1 - ACC ＜2Ω
ON AM1 - ACC - IG1， AM2 - IG2 ＜2Ω

91
START AM1 - IG1 - ST1， AM2 - IG2 - ST2 ＜2Ω
If the resistance is out of the specification, replace the ignition switch assy. (Refer to “Chapter 91
vehicle control system - ignition switch assy, removal & installation and disassembly & reassembly”)
91-2 VEHICLE CONTROL SYSTEM - IGNITION SWITCH ASSY
REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY

overhaul”)
overhaul”)
replacement”)
8. REMOVE STEERING COLUMN LOWER COVER. (Refer to “Chapter 51 steering column -
steering column assy, replacement”)
9. REMOVE IGNITION SWITCH ASSY.

(a) Remove the harness clip.
(b) Using an allen wrench (key), loosen 2 bolts.

(c) Remove the ignition switch assy.

CAUTION
• During this procedure, the ignition switch assy
connector is not disconnected. 91
• Do not drag the wire harness.
• Make sure there is no interference between wire
harness and parts around.
NOTE
Store the ignition switch assy carefully.
(d) Disconnected 3 connectors:

• Disconnect the ignition switch connector.
• Disconnect the ignition key position switch connector.
• Disconnect the ignition keyhole illumination connector.
NOTE
Store the ignition switch assy carefully.
10. DISASSEMBLE IGNITION SWITCH ASSY. 91

(a) Loosen the screw.
(b) Remove the ignition switch lamp.
(c) Insert the ignition key, then turn the ignition switch to the
“ACC” position.
(d) Using a stick, press the ignition switch lock latch.
(e) Pull out the ignition switch.
(f) Loosen 2 screws.
(g) Remove the ignition switch connector.
11. REASSEMBLE IGNITION SWITCH ASSY.

(a) Install the ignition switch connector.
NOTE
Insert and turn the ignition key to align the key sets.
91
(c) Insert the ignition key, then turn the ignition switch to the
“ACC” position.
(d) Install the ignition switch.
NOTE
If hear a “click”, the ignition switch is installed properly.
(e) Install the ignition switch lamp.

91
(f) Tighten the screw.
12. INSTALL IGNITION SWITCH ASSY.

(a) Connect 3 connectors:
• Connect the ignition switch connector.
• Connect the ignition key position switch connector.
• Connect the ignition keyhole illumination connector.
CAUTION
• Make sure the wire harness does not interfere with
parts around.
(b) Align the lock slot on the steering column assy and the latch
block on the ignition switch assy.
NOTE
The ignition switch lock latch will extrude only when the
ignition key is pulled out.
(c) Position the ignition switch assy properly.

CAUTION
• Make sure the wire harness does not interfere with
parts around.
(d) Using an allen wrench (key), tighten 2 bolts.

(e) Tighten the harness clip.

NOTE
Check for damage, and replace with a new harness clip if
necessary. 91
13. INSTALL STEERING COLUMN LOWER COVER. (Refer to “Chapter 51 steering column - steering
column assy, replacement”)
replacement”)
overhaul”)
overhaul”)
18. CONNECT BATTERY POSITIVE CABLE. (If airbag is equipped, refer to “Chapter 20 starting and 91
replacement”)
MEMO
INDEX 1
（ORGNIZED ALPHABETICALLY）
A COMPONENTS(FRONT HEATER ASSY) ................................. 61-16 1
COMPONENTS(HEATER PIPE) ................................................ 61-10
A - ENGINE ROOM WIRE HARNESS COMPONENTS(HORN) 2
(CONNECTOR VIEWS) ............................................................71-173 COMPONENTS(INSTRUMENT CLUSTER) .............................. 83-36 1
A - ENGINE ROOM WIRE HARNESS COMPONENTS(LIGHTING SYSTEM) ......................................... 64-2
(WIRE HARNESS & CONNECTOR LOCATION VIEWS) ........71-242 COMPONENTS(MIDDLE PLATFORM) ..................................... 83-26 1
ACCUMULATOR ........................................................................61-80 COMPONENTS(OUTSIDE MIRROR) ........................................ 82-20
ADJUSTMENT(DRIVER / ASSISTANT DRIVER SEAT BELT) ....63-5 COMPONENTS(PASSENGER SEAT BELT) ............................... 63-7
ADJUSTMENT(DRIVER / ASSISTANT DRIVER SEAT) ..............84-3 COMPONENTS(PASSENGER SEAT) ....................................... 84-25 1
ADJUSTMENT(ENGINE HOOD) ..................................................87-1 COMPONENTS(POWER WINDOW) ........................................... 82-1
ADJUSTMENT(FRONT COMBINATION LAMP ASSY LH) ..........64-6 COMPONENTS(REAR BUMPER ASSY) .................................. 88-17
ADJUSTMENT(FRONT DOOR) ...................................................87-7 COMPONENTS(REAR HATCH LOCK) ..................................... 85-16 1
ADJUSTMENT(FRONT FOG LAMP ASSY LH) .........................64-16 COMPONENTS(REAR HATCH) ................................................ 87-21
ADJUSTMENT(REAR HATCH) ..................................................87-22 COMPONENTS(REAR HEATER ASSY) ................................... 61-26 1
ADJUSTMENT(SLIDING DOOR) ...............................................87-16 COMPONENTS(REAR LOWER VIEW MIRROR) ..................... 82-30
ADJUSTMENT(WASHER NOZZLE) ...........................................65-34 COMPONENTS(REAR VIEW MIRROR) .................................... 82-26
ANCHOR ADJUSTER ASSY ......................................................63-27 COMPONENTS(REAR WINDOW GLASS) ................................ 82-14 1
ANTENNA AMPLIFIER ASSY ....................................................66-10 COMPONENTS(REVERSE RADAR) 7
ANTI-LOCK BRAKE SYSTEM(WIRING DIAGRAM) ..................71-46 COMPONENTS(ROOF GUARD BOARD ASSY) ....................... 88-52
AUDIO SYSTEM ...........................................................................66-1 COMPONENTS(SIDE WALL GUARD BOARD) ........................ 88-37 1
AUDIO(WIRING DIAGRAM) .....................................................71-171 COMPONENTS(SIDE WINDOW GLASS) ................................. 82-17
A/C CONTROLLER .....................................................................61-83 COMPONENTS(SLIDING DOOR LOCKS) .................................. 85-9 1
COMPONENTS(SLIDING DOOR) ............................................. 87-14
B COMPONENTS(SPOILER ASSY) ............................................. 88-13
COMPONENTS(STEP BOARD) ................................................ 88-24 1
B - FAN WIRE HARNESS(CONNECTOR VIEWS) ..................71-178 COMPONENTS(SUN VISOR ASSY) ......................................... 88-21
B - FAN WIRE HARNESS(WIRE HARNESS & CONNECTOR LOCA- COMPONENTS(VEHICLE DOOR INNER GUARD BOARD) .... 88-28
TION VIEWS) ............................................................................71-242 COMPONENTS(WINDSHIELD) ................................................... 82-8 1
BUCKLE ASSY ...........................................................................63-19 COMPONENTS(WIPER AND WASHER SYSTEM) .................... 65-5
COMPRESSOR .......................................................................... 61-66
C COMPRESSOR OIL ................................................................... 61-39
1
CONDENSER ............................................................................. 61-74
C - INSTRUMENT PANEL WIRE HARNESS 1
CONNECTOR VIEWS .............................................................. 71-173
(INCLUDING DIAGNOSIS WIRE HARNESS & COMBINED
CONNECTOR VIEWS SECTION EXAMPLE
DISPLAY WIRE HARNESS)(WIRE HARNESS & CONNECTOR
(HOW TO USE THIS MANUAL) ................................................... 71-7
LOCATION VIEWS) ..................................................................71-244 1
COOLING FAN(WIRING DIAGRAM) ......................................... 71-43
(CONNECTOR VIEWS) ............................................................71-179 D
CARPET ......................................................................................88-47 1
CD ASSY ......................................................................................66-2 D - REAR FOG LAMP WIRE HARNESS
CHARGING SYSTEM(WIRING DIAGRAM) ...............................71-73 (CONNECTOR VIEWS) ........................................................... 71-203 1
CLOCK SPRING .........................................................................62-14 D - REAR FOG LAMP WIRE HARNESS
COMBINED DISPLAY 4 (WIRE HARNESS & CONNECTOR LOCATION VIEWS) ........ 71-248
COMMUNICATION SYSTEM(WIRING DIAGRAM) ..................71-153 DASHBOARD ............................................................................... 83-1 1
COMPONENTS(ACCUMULATOR) ............................................61-80 DISPOSAL(HORN SWITCH ASSY) ........................................... 62-10
COMPONENTS(AUDIO SYSTEM) ...............................................66-1 DRIVER / ASSISTANT DRIVER SEAT ........................................ 84-2
COMPONENTS(A/C CONTROLLER) ........................................61-83 DRIVER / ASSISTANT DRIVER SEAT BELT .............................. 63-4 1
COMPONENTS(A/C PIPE) .........................................................61-41
COMPONENTS(CARPET) .........................................................88-47 E
1
COMPONENTS(COMBINED DISPLAY) 4
COMPONENTS(COMPRESSOR) ..............................................61-66 E - ENGINE CONTROL WIRE HARNESS
COMPONENTS(CONDENSER) .................................................61-74 (WITH BJ493ZQ3 ENGINE)(WIRE HARNESS &
COMPONENTS(DASHBOARD) ...................................................83-2 CONNECTOR LOCATION VIEWS) ......................................... 71-252
COMPONENTS(DRIVER / ASSISTANT DRIVER SEAT BELT) ..63-4 E - ENGINE CONTROL WIRE HARNESS
COMPONENTS(DRIVER / ASSISTANT DRIVER SEAT) ............84-2 (WITH 4G63/4G64 ENGINE)(WIRE HARNESS & CONNECTOR
COMPONENTS(ELECTRIC DEVICE ACCESSORIES) .............66-12 LOCATION VIEWS) ................................................................ 71-250
COMPONENTS(ENGINE HOOD LOCK) ....................................85-22 E - ENGINE CONTROL WIRE HARNESS
COMPONENTS(FRONT BUMPER ASSY) ...................................88-4 (CONNECTOR VIEWS) ........................................................... 71-204
COMPONENTS(FRONT DOOR LOCKS) .....................................85-1 E - ENGINE ROOM SUB-HARNESS(WIRE HARNESS &
COMPONENTS(FRONT DOOR) ..................................................87-5 CONNECTOR LOCATION VIEWS) ........................................ 71-252
COMPONENTS(FRONT EVAPORATOR ASSY) .......................61-51 ELECTRIC DEVICE ACCESSORIES ........................................ 66-12
COMPONENTS(FRONT GRILLE) ................................................88-1 ENGINE CONTROL SYSTEM(WIRING DIAGRAM) .................. 71-29
ENGINE HOOD ............................................................................ 87-1
ENGINE HOOD LOCK ............................................................... 85-22 INSPECTION(WIPER AND WASHER SYSTEM) .........................65-7
INSTRUMENT CLUSTER ...........................................................83-30
F INSTRUMENT CLUSTER(WIRING DIAGRAM) .........................71-55
INTRODUCTION(HOW TO USE THIS MANUAL) ........................71-1
F - ROOF WIRE HARNESS(CONNECTOR VIEWS) ............... 71-214
F - ROOF WIRE HARNESS(WIRE HARNESS & CONNECTOR K
LOCATION VIEWS) ................................................................. 71-254
FRONT BLOWER ....................................................................... 61-71 K - CHASSIS WIRE HARNESS RH(CONNECTOR VIEWS) ...71-227
FRONT BUMPER ASSY .............................................................. 88-4 K - CHASSIS WIRE HARNESS RH
FRONT COMBINATION LAMP ASSY LH .................................... 64-4 (WIRE HARNESS & CONNECTOR LOCATION VIEWS) ........71-257
FRONT COMBINATION LAMP BULB LH .................................... 64-7
FRONT DOOR ............................................................................. 87-5 L
FRONT DOOR LOCKS ................................................................ 85-1
FRONT EVAPORATOR ASSY ................................................... 61-51 L - CHASSIS WIRE HARNESS LH(CONNECTOR VIEWS) ....71-229
FRONT FOG LAMP ASSY LH ................................................... 64-14 L - CHASSIS WIRE HARNESS LH
FRONT FOG LAMP BULB LH .................................................... 64-17 (WIRE HARNESS & CONNECTOR LOCATION VIEWS) ........71-254
FRONT GRILLE ........................................................................... 88-1 LICENCE LAMP ASSY LH .........................................................64-28
FRONT HEATER ASSY ............................................................. 61-16 LIGHTING SYSTEM .....................................................................64-1
FRONT INDOOR LAMP ASSY .................................................. 64-32 LIGHTING SYSTEM(WIRING DIAGRAM) ..................................71-77
FRONT INDOOR LAMP BULB ................................................... 64-35 M
FRONT SPEAKER ASSY LH ....................................................... 66-6
FUSE AND RELAY LOCATIONS M - FRONT DOOR WIRE HARNESS RH
(HOW TO USE THIS MANUAL) ................................................. 71-10
(CONNECTOR VIEWS) ............................................................71-231
G M - FRONT DOOR WIRE HARNESS RH
(WIRE HARNESS & CONNECTOR LOCATION VIEWS) ........71-259
G - REAR BODY WIRE HARNESS RH MIDDLE PLATFORM ..................................................................83-26
(CONNECTOR VIEWS) ........................................................... 71-218 N
(WIRE HARNESS & CONNECTOR LOCATION VIEWS) ........ 71-257
GLOSSARY OF TERMS AND SYMBOLS
(CONNECTOR VIEWS) ............................................................71-233
(HOW TO USE THIS MANUAL) ................................................... 71-8 N - FRONT DOOR WIRE HARNESS LH
GROUND POINT(WIRING DIAGRAM) ...................................... 71-24
(WIRE HARNESS & CONNECTOR LOCATION VIEWS) ........71-260
H O
ON-VEHICLE INSPECTION(CONDENSER) ..............................61-75
(CONNECTOR VIEWS) ........................................................... 71-222 ON-VEHICLE INSPECTION
(HEATER AND AIR CONDITIONING) ..........................................61-8
ON-VEHICLE INSPECTION(REFRIGERANT) ...........................61-30
HEADLAMP DIMMER SWITCH ASSY ...................................... 64-46 ON-VEHICLE INSPECTION
HEATER AND AIR CONDITIONING ............................................ 61-1
(SUPPLEMENTAL RESTRAINT SYSTEM) ..................................62-4
HEATER AND AIR CONDITIONING CONTROL SYSTEM
OVERHAUL(COMPRESSOR) ....................................................61-67
(WIRING DIAGRAM) ................................................................ 71-123 OVERHAUL(CONDENSER) .......................................................61-76
HEATER PIPE ............................................................................ 61-10
OVERHAUL(RETRACTOR ASSY) .............................................63-22
HIGH-MOUNTED STOP LAMP ASSY ....................................... 64-27
OVERHAUL(SLIDING ROOF ASSY) ...........................................86-2
HORN 1 OUTSIDE MIRROR ....................................................................82-20
HORN SWITCH ASSY ................................................................. 62-6
OUTSIDE MIRROR AND REAR WINDOW DEFROSTER
HOW TO USE THIS MANUAL ..................................................... 71-1
(WIRING DIAGRAM) ................................................................71-147
J P
I - REAR HATCH WIRE HARNESS #1 PASSENGER SEAT ...................................................................84-25
(CONNECTOR VIEWS) ........................................................... 71-225
PASSENGER SEAT BELT ...........................................................63-7
POWER DOOR LOCK(WIRING DIAGRAM) ............................71-107
(WIRE HARNESS & CONNECTOR LOCATION VIEWS) ........ 71-248 POWER MIRROR(WIRING DIAGRAM) ...................................71-165
POWER SOCKET(WIRING DIAGRAM) ...................................71-159
(CONNECTOR VIEWS) ........................................................... 71-226
POWER SOURCE SECTION EXAMPLE
J - REAR HATCH WIRE HARNESS #2 (HOW TO USE THIS MANUAL) ...................................................71-6
POWER SOURCE(WIRING DIAGRAM) ....................................71-18
IGNITION KEY POSITION REMIND CONTROLLER
POWER WINDOW ........................................................................82-1
(WIRING DIAGRAM) ................................................................ 71-163 POWER WINDOW CONTROL(WIRING DIAGRAM) ...............71-120
IGNITION SWITCH ASSY ............................................................ 91-1
PRECAUTION(DASHBOARD) .....................................................83-1
INDOOR ROOF LAMP ASSY LH ............................................... 64-37
PRECAUTION(HEATER AND AIR CONDITIONING) ..................61-1
INDOOR ROOF LAMP BULB LH ............................................... 64-38 PRECAUTION(INSTRUMENT CLUSTER) .................................83-30
INSPECTION(COMPRESSOR OIL) .......................................... 61-39
PRECAUTION(LIGHTING SYSTEM) ...........................................64-1
INSPECTION(IGNITION SWITCH ASSY) ................................... 91-1
PRECAUTION(SEAT BELT SYSTEM) .........................................63-1
INSPECTION(POWER WINDOW) ............................................... 82-2 PRECAUTION(SEAT) ...................................................................84-1
INSPECTION(SEAT BELT WARNING SYSTEM) ........................ 63-3
PRECAUTION(SUPPLEMENTAL RESTRAINT SYSTEM) ..........62-1
INSPECTION(WASHER NOZZLE) ............................................ 65-33
PRECAUTION(WIPER AND WASHER SYSTEM) .......................65-1
PROBLEM SYMPTOMS TABLE(HEATER AND AIR CONDITIONING) REPLACEMENT(HORN SWITCH ASSY) .................................... 62-6
.......................................................................................................61-3 REPLACEMENT(HORN) 3
PROBLEM SYMPTOMS TABLE(HORN) 1 REPLACEMENT(INDOOR ROOF LAMP ASSY LH) ................. 64-37
PROBLEM SYMPTOMS TABLE(INSTRUMENT CLUSTER) .....83-31 REPLACEMENT(INDOOR ROOF LAMP BULB LH) .................. 64-38
PROBLEM SYMPTOMS TABLE(REVERSE RADAR) 6 REPLACEMENT(INSTRUMENT CLUSTER) ............................. 83-37 1
PROBLEM SYMPTOMS TABLE(SEAT BELT WARNING SYSTEM) .. REPLACEMENT(LICENCE LAMP ASSY LH) ............................ 64-28
63 .......................................................................................................-2 REPLACEMENT(MIDDLE PLATFORM) .................................... 83-27
PROBLEM SYMPTOMS TABLE(SLIDING ROOF ASSY) ............86-1 REPLACEMENT(OUTSIDE MIRROR) ....................................... 82-21 1
PROBLEM SYMPTOMS TABLE(WIPER AND WASHER SYSTEM) .. REPLACEMENT(POWER WINDOW) .......................................... 82-3
65 .......................................................................................................-2 REPLACEMENT(RCM) .............................................................. 62-17
REPLACEMENT(REAR BUMPER ASSY) ................................. 88-18
1
Q REPLACEMENT(REAR COMBINATION LAMP ASSY LH) ....... 64-20
REPLACEMENT(REAR FOG LAMP ASSY LH) ........................ 64-30 1
Q - FRONT BODY WIRE HARNESS(CONNECTOR VIEWS) ..71-235 REPLACEMENT(REAR FOG LAMP SWITCH ASSY) ............... 64-47
Q - FRONT BODY WIRE HARNESS(WIRE HARNESS & CONNEC- REPLACEMENT(REAR HATCH LOCK) .................................... 85-17
TOR LOCATION VIEWS) .........................................................71-261 REPLACEMENT(REAR HATCH) ............................................... 87-24 1
R REPLACEMENT(REAR HEATER ASSY) .................................. 61-27
REPLACEMENT(REAR INDOOR LAMP ASSY) ....................... 64-40
REPLACEMENT(REAR INDOOR LAMP BULB) ........................ 64-42
1
RCM ............................................................................................62-17
REAR BLOWER ..........................................................................61-72 REPLACEMENT(REAR SPEAKER ASSY LH) ............................ 66-8
REAR BUMPER ASSY ...............................................................88-17 REPLACEMENT(REAR VIEW MIRROR) .................................. 82-27 1
REAR COMBINATION LAMP ASSY LH .....................................64-20 REPLACEMENT(REAR WINDOW GLASS) .............................. 82-15
REAR FOG LAMP ASSY LH ......................................................64-30 REPLACEMENT(REFRIGERANT) ............................................ 61-36
REPLACEMENT(REPLACEMENT) ........................................... 82-31 1
REAR FOG LAMP SWITCH ASSY .............................................64-47
REAR HATCH .............................................................................87-21 REPLACEMENT(REVERSE RADAR) 8
REAR HATCH LOCK ..................................................................85-16 REPLACEMENT(ROOF GUARD BOARD ASSY) ..................... 88-54
REPLACEMENT(SIDE WALL GUARD BOARD) ....................... 88-38
1
REAR HEATER ASSY ................................................................61-26
REAR INDOOR LAMP ASSY .....................................................64-40 REPLACEMENT(SIDE WINDOW GLASS) ................................ 82-18
REAR INDOOR LAMP BULB ......................................................64-42 REPLACEMENT(SLIDING DOOR LOCKS) ............................... 85-10 1
REAR LOWER VIEW MIRROR ..................................................82-30 REPLACEMENT(SLIDING DOOR) ............................................ 87-19
REAR SPEAKER ASSY LH ..........................................................66-8 REPLACEMENT(SPOILER ASSY) ............................................ 88-14
REPLACEMENT(STEP BOARD) ............................................... 88-25 1
REAR VIEW MIRROR ................................................................82-26
REAR WINDOW GLASS ............................................................82-14 REPLACEMENT(STEP LAMP ASSY) ....................................... 64-43
REFRIGERANT ..........................................................................61-30 REPLACEMENT(STEP LAMP BULB) ........................................ 64-45
REPLACEMENT(SUN VISOR ASSY) ........................................ 88-22
1
REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEM-
BLY(IGNITION SWITCH ASSY) ...................................................91-2 REPLACEMENT
REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEML- (TURN SIGNAL LAMP IN OUTSIDE MIRROR) ......................... 64-19 1
BY((DRIVER / ASSISTANT DRIVER SEAT)) ...............................84-8 REPLACEMENT(VEHICLE DOOR INNER GUARD BOARD) ... 88-30
REPLACEMENT(ACCUMULATOR) ...........................................61-81 REPLACEMENT(VENT DUCT) .................................................... 61-9
REPLACEMENT(WHEEL MUDGUARD) ..................................... 88-9 1
REPLACEMENT(ANCHOR ADJUSTER ASSY) .........................63-27
REPLACEMENT(ANTENNA AMPLIFIER ASSY) .......................66-10 REPLACEMENT(WINDSHIELD) .................................................. 82-9
REPLACEMENT(A/C CONTROLLER) .......................................61-84 REPLACEMENT(WIPER ASSY) ................................................ 65-16
REPLACEMENT(WIPER BLADE WITH BRACKET ASSY) ....... 65-32
1
REPLACEMENT(A/C PIPE) ........................................................61-42
REPLACEMENT(BUCKLE ASSY) ..............................................63-19 REPLACEMENT(WIPER LINK ASSY) ....................................... 65-28
REPLACEMENT(CARPET) ........................................................88-48 REPLACEMENT(WIPER MOTOR ASSY) ................................. 65-21 1
REPLACEMENT(CD ASSY) .........................................................66-2 RETRACTOR ASSY ................................................................... 63-22
REPLACEMENT(CLOCK SPRING) ............................................62-14 REVERSE RADAR 6
ROOF GUARD BOARD ASSY ................................................... 88-52 1
REPLACEMENT(COMBINED DISPLAY) 5
REPLACEMENT(COMPRESSOR OIL) ......................................61-40 S
REPLACEMENT(DASHBOARD) ..................................................83-3 1
REPLACEMENT(ELECTRIC DEVICE ACCESSORIES) ............66-13 SEAT ............................................................................................ 84-1
REPLACEMENT(ENGINE HOOD) ...............................................87-3 SEAT BELT SYSTEM .................................................................. 63-1
REPLACEMENT(FRONT BLOWER) .............................. 61-71, 61-72 SEAT BELT WARNING SYSTEM ................................................ 63-2
1
REPLACEMENT(FRONT BUMPER ASSY) .................................88-5 SIDE WALL GUARD BOARD ..................................................... 88-37
REPLACEMENT(FRONT COMBINATION LAMP ASSY LH) .......64-4 SIDE WINDOW GLASS ............................................................. 82-17 1
REPLACEMENT(FRONT COMBINATION LAMP BULB LH) .......64-7 SLIDING DOOR ......................................................................... 87-14
REPLACEMENT(FRONT DOOR LOCKS) ...................................85-2 SLIDING DOOR LOCKS .............................................................. 85-9
REPLACEMENT(FRONT DOOR) ...............................................87-11 SLIDING ROOF ASSY ................................................................. 86-1
REPLACEMENT(FRONT FOG LAMP ASSY LH) .......................64-14 SLIDING ROOF(WIRING DIAGRAM) ...................................... 71-161
REPLACEMENT(FRONT FOG LAMP BULB LH) .......................64-17 SPOILER ASSY ......................................................................... 88-13
REPLACEMENT(FRONT GRILLE) ...............................................88-2 STARTING SYSTEM(WIRING DIAGRAM) ................................ 71-69
REPLACEMENT(FRONT HEATER ASSY) ................................61-17 STEP BOARD ............................................................................ 88-24
REPLACEMENT(FRONT INDOOR LAMP ASSY) ......................64-32 STEP LAMP ASSY ..................................................................... 64-43
REPLACEMENT(FRONT INDOOR LAMP BULB) ......................64-35 STEP LAMP BULB ..................................................................... 64-45
REPLACEMENT(FRONT SPEAKER ASSY LH) ..........................66-6 SUN VISOR ASSY ..................................................................... 88-21
REPLACEMENT(HEADLAMP DIMMER SWITCH ASSY) ..........64-46 SUPPLEMENTAL RESTRAINT SYSTEM .................................... 62-1
REPLACEMENT(HEATER PIPE) ...............................................61-12 SUPPLEMENTAL RESTRAINT SYSTEM
REPLACEMENT(HIGH-MOUNTED STOP LAMP ASSY) ..........64-27 (WIRING DIAGRAM) .................................................................. 71-52
SYSTEM PERFORMANCE VEHICLE DOOR INNER GUARD BOARD .................................88-28
(SUPPLEMENTAL RESTRAINT SYSTEM) ................................. 62-3 VENT DUCT .................................................................................61-9
SYSTEM PRINCIPLES WHEEL MUDGUARD ...................................................................88-9
(SUPPLEMENTAL RESTRAINT SYSTEM) ................................. 62-2 WINDSHIELD ...............................................................................82-8
SYSTEM WIRING DIAGRAM SECTION EXAMPLE WIPER AND WASHER SYSTEM .................................................65-1
(HOW TO USE THIS MANUAL) ................................................... 71-2 WIPER AND WASHER(WIRING DIAGRAM) ...........................71-168
WIPER ASSY ..............................................................................65-16
T WIPER BLADE WITH BRACKET ASSY .....................................65-32
WIPER LINK ASSY .....................................................................65-28
TURN SIGNAL LAMP IN OUTSIDE MIRROR ........................... 64-19 WIPER MOTOR ASSY ...............................................................65-21
W WIRE HARNESS & CONNECTOR LOCATION VIEWS ...........71-242
WIRING DIAGRAM .....................................................................71-18
WASHER NOZZLE ..................................................................... 65-33

MPX English Final Version VOLUME 3

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Edition: September 2010 VOLUME 1

Printing: October 2010 INTRODUCTION 01

PROBLEM SYMPTOMS TABLE

Symptom Suspect Area Reference

2. Clutch disk (Worn) Chapter 42 clutch - clutch subassy, overhaul

Clutch slips 3. Flywheel (Warping) Chapter 42 clutch - clutch subassy, overhaul

4. Clutch cover (Warping) Chapter 42 clutch - clutch subassy, overhaul

5. Diaphragm spring (Failure) Chapter 42 clutch - clutch subassy, overhaul

2. Diaphragm spring (Failure) Chapter 42 clutch - clutch subassy, overhaul

Chapter 42 clutch - clutch master cylinder assy,

Chapter 42 clutch - clutch slave cylinder assy,

6. Clutch disk (Worn) Chapter 42 clutch - clutch subassy, overhaul

7. Clutch cover (Warping) Chapter 42 clutch - clutch subassy, overhaul

8. Clutch release bearing (Worn) Chapter 42 clutch - clutch subassy, overhaul

9. Clutch release fork (Worn) Chapter 42 clutch - clutch subassy, overhaul

1. Torsion spring (Fracture) Chapter 42 clutch - clutch subassy, overhaul

2. Clutch disk (Worn) Chapter 42 clutch - clutch subassy, overhaul

4. Clutch pedal (Warping) Chapter 42 clutch - clutch pedal, replacement

1. Clutch disk (Worn or Warping) Chapter 42 clutch - clutch subassy, overhaul

2. Flywheel (Worn) Chapter 42 clutch - clutch subassy, overhaul

3. Clutch cover (Worn) Chapter 42 clutch - clutch subassy, overhaul

5. Diaphragm spring (Warping) Chapter 42 clutch - clutch subassy, overhaul

6. Engine mount (Loose) -

2. BLEED CLUTCH SLAVE CYLINDER ASSY.

3. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR.

1 Return spring 5 Nut

2 Clutch Pedal Pin 6 Cotter Pin

3 Bolt 7 Clutch Master Cylinder Push Rod Pin

4 Clutch Pedal Support 8 Clutch Pedal

3. INSPECT CLUTCH PEDAL FREE PLAY AND PUSH

2. REMOVE CLUTCH PEDAL RETURN SPRING.

3. REMOVE CLUTCH MASTER CYLINDER PUSH ROD

(b) Remove the clutch master cylinder push rod and

4. LOOSEN NUT AND REMOVE CLUTCH PEDAL PIN

5. REMOVE CLUTCH PEDAL.

6. INSTALL CLUTCH PEDAL PIN AND BUSHING AND

7. INSTALL CLUTCH MASTER CYLINDER PUSH ROD

(b) Install the cotter pin of the push rod.

8. INSTALL CLUTCH PEDAL RETURN SPRING.

9. INSTALL ECM COVER.

CLUTCH MASTER CYLINDER ASSY

1 Clutch Master Cylinder Housing 7 Dust Boot

2 Spring 8 Clutch Master Cylinder Push Rod Pin

3 Piston 9 Push Rod Clevis

4 Washer 10 Cotter Pin

5 Snap Ring 11 Lock Nut

6 Push Rod 12 Nut

2. REMOVE CLUTCH MASTER CYLINDER ASSY.

(c) Loosen the clutch master cylinder assy nut positioned in

(d) Loosen the clutch master cylinder assy nut positioned in

(e) Remove clutch master cylinder assy.

3. INSTALL CLUTCH MASTER CYLINDER ASSY.

(b) Tighten the clutch master cylinder assy nut positioned in

(c) Connect the clutch master cylinder tube to clutch master

(d) Connect the hose of brake fluid reservoir, then install

CLUTCH SLAVE CYLINDER ASSY

1 Dust Boot 4 Spring

3 Piston 6 Bleeding Plug

2. REMOVE CLUTCH SLAVE CYLINDER ASSY.

(b) Remove 2 bolts from clutch slave cylinder.